APPEA Lifitng and Rigging Guidelines PDF [PDF]

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Australian Petroleum Production & Exploration Association Limited

GUIDELINES FOR LIFTING EQUIPMENT

_______________________________________________

Australian Petroleum Production & Exploration Association Limited Level 3, 24 Marcus Clarke St GPO Box 2201 CANBERRA ACT 2600 CANBERRA ACT 2601 Telephone: +61 2 6247 0960 Facsimile +61 2 6247 0548 INTERNET http://www.appea.com.au Email: [email protected] ACN 000 292 713

ISBN 0 908277 21 0

Issued: August 1999

APPEA

Guidelines for Lifting Equipment

PREFACE Lifting operations in the offshore petroleum industry represent potentially one of the highest risk activities in the industry. Accordingly many standards and individual company guidelines exist to ensure that lifting operations are performed safely using appropriate equipment. As well as offshore lifting this guideline does cover some aspects of lifting operations at onshore sites. In particular personnel competency requirements, registers of lifting equipment and operational aspects for lifting devices including mobile cranes are covered. During the preparation of the guideline the technical working group recognised that onshore lifting practices were generally well established and that a uniform standard already existed. This guideline is intended only to supplement and does not seek to alter these well established onshore lifting practices. APPEA has issued these guidelines to facilitate consistent lifting practices across the petroleum industry, particularly for offshore operations. These guidelines establish appropriate design requirements for “Lifting Gear” reflecting the dynamic effects of lifting operations from supply vessels along with guidance on equipment marking, registers, inspection testing and maintenance. They also describe the broad expectations for competencies of personnel associated with lifting activities. The purpose of these guidelines is to provide operators, contractors and vendors working in the offshore petroleum industry clear and consistent guidance on the expected standards to ensure safe lifting operations, thereby minimising risks to personnel and assets.

APPEA WORKING GROUP MEMBERS APPEA: AOS: BHPP: ESSO: IADC: SCHLUMBERGER: TIDEWATER: WOODSIDE: NOBLES BHP LIFTING

David Ffrench (ESSO) Captain Bill Korevaar Peter Rogers Ray Lindner Dan Ahern (ATWOOD OCEANICS) Roberto Nazareno Andy Green Mike Reklitis Peter Campbell Andrew Jarvie

Technical Advisers: ESSO: TRANSFIELD/WORLEY

Doug Williams Peter Lardi

Disclaimer The use of these Guidelines do not affect the responsibility of individual operating companies or, their contractors to carry out operations safely having regard to their duty of care responsibilities, and to observe statutory requirements. APPEA cannot accept any responsibility for any incident or consequence thereof, whether or not in violation of any law or regulation, which arises or is alleged to have arisen from the use of these Guidelines. ____________________________________________________________________________ August 1999

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APPEA

Guidelines for Lifting Equipment

CONTENTS

1

INTRODUCTION....................................................................................................................................................5 1.1 1.2 1.3 1.4

2

PURPOSE AND SCOPE .............................................................................................................................................5 LIFTING EQUIPMENT TERMINOLOGY......................................................................................................................6 RELATIONSHIP WITH REGULATIONS.......................................................................................................................7 MANAGEMENT SYSTEM .........................................................................................................................................7

COMPETENCY STANDARDS .............................................................................................................................8 2.1 MANAGEMENT RESPONSIBILITIES ..........................................................................................................................8 2.2 COMPETENCE OF CRANE AND FORKLIFT OPERATORS, RIGGERS AND DOGGERS ....................................................8 2.3 MAINTAINERS OF LIFTING EQUIPMENT ..................................................................................................................8 2.4 INSPECTORS OF LIFTING EQUIPMENT .....................................................................................................................9 2.4.1 Visual check.....................................................................................................................................................9 2.4.2 Lifting Equipment Inspection Bodies...............................................................................................................9 2.5 NON DESTRUCTIVE TESTING (NDT) LABORATORIES ............................................................................................9 2.5.1 Proof Load Testing Laboratories ..................................................................................................................10 2.6 DESIGNERS OF LIFTING GEAR ..............................................................................................................................10

3

REGISTERS OF LIFTING EQUIPMENT.........................................................................................................11 3.1 3.2 3.3

4

INTRODUCTION ....................................................................................................................................................11 LIFTING EQUIPMENT REGISTER............................................................................................................................11 LIFTING EQUIPMENT REGISTER CONTENTS ..........................................................................................................11

DESIGN OF OFFSHORE LIFTING DEVICES ................................................................................................13 4.1 INTRODUCTION AND SCOPE .................................................................................................................................13 4.2 DESIGN, MANUFACTURE AND INSTALLATION (GENERAL)...................................................................................13 4.3 CRANES ...............................................................................................................................................................13 4.3.1 Crane configuration ......................................................................................................................................15 4.3.2 Performance criteria (Minimum Requirements)...........................................................................................15 4.3.3 Environmental criteria ..................................................................................................................................16 4.3.4 Utilities available ..........................................................................................................................................16 4.4 MOBILE CRANES ..................................................................................................................................................17 4.5 GANTRY CRANES, LIFTING BEAMS AND LIFTING AIDS ........................................................................................17 4.6 LIFTING POINTS ...................................................................................................................................................17 4.7 HOISTING EQUIPMENT (MANUALLY OPERATED) .................................................................................................18 4.8 MAN-RIDING EQUIPMENT ....................................................................................................................................18 4.8.1 Cranes Used for Man Riding Operations ......................................................................................................18 4.8.2 Tugger and Man Riding Winches ..................................................................................................................19 4.9 SURVEYS AND INSPECTION ..................................................................................................................................19 4.10 DOCUMENTATION ................................................................................................................................................20

5

DESIGN OF OFFSHORE LIFTING GEAR.......................................................................................................21 5.1 INTRODUCTION ....................................................................................................................................................21 5.2 DESIGN APPROACH FOR ENGINEERED LIFTS ........................................................................................................21 5.3 OVER CHART LIFTS .............................................................................................................................................22 5.4 DESIGN OF RIGGING .............................................................................................................................................22 5.5 ACCESS TO CRANE HOOK FOR MARINE CREWS – FIFTH LEG ASSEMBLIES ..........................................................25 5.6 DIAGONALLING....................................................................................................................................................25 5.7 SPECIFIC REQUIREMENTS FOR OFFSHORE USE .....................................................................................................26 5.7.1 Synthetic Slings (Refer AS 1353.17.2-1997, AS 4497.1&.2 -1997) ...............................................................26 5.7.2 Safety Shackles ..............................................................................................................................................26 5.7.3 Eyebolts .........................................................................................................................................................26 5.7.4 Chain Slings ..................................................................................................................................................26

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APPEA Guidelines for Lifting Equipment 5.8 DESIGN OF OFFSHORE CONTAINER PADEYES & THEIR ATTACHMENT .................................................................27 5.9 DESIGN OF LIFTED EQUIPMENT (OFFSHORE CONTAINERS) ..................................................................................27 5.10 SEA (ISO) CONTAINERS.......................................................................................................................................28 5.11 DESIGN OF SUB-SEA LIFTS ...................................................................................................................................29 5.12 MATERIALS OF CONSTRUCTION AND FABRICATION REQUIREMENTS ...................................................................30 5.13 DOCUMENTATION – NEW BUILD LIFTED EQUIPMENT..........................................................................................30 5.14 DOCUMENTATION FOR EXISTING LIFTED EQUIPMENT .........................................................................................32 5.15 INITIAL LOAD TESTS (OFFSHORE CONTAINERS INCLUDING ISO CONTAINERS) ...................................................33 5.16 NON DESTRUCTIVE TESTING (OFFSHORE CONTAINERS INCLUDING ISO CONTAINERS).......................................33 6

DESIGN OF TANKS FOR FLUIDS ....................................................................................................................35

7

MARKING OF LIFTING EQUIPMENT ...........................................................................................................37 7.1 GENERAL .............................................................................................................................................................37 7.2 MARKING OF LIFTING DEVICES ...........................................................................................................................37 7.2.1 Fixed Location Padeyes.................................................................................................................................37 7.3 MARKING OF LIFTED EQUIPMENT ........................................................................................................................37 7.4 CONTAINER AND ROOF IDENTIFICATION MARKINGS ...........................................................................................37 7.5 LIFTING FRAME AND BEAM MARKINGS ...............................................................................................................38 7.6 MARKING OF RIGGING .........................................................................................................................................38

8

PERIODIC INSPECTION, TESTING AND MAINTENANCE .......................................................................39 8.1 GENERAL .............................................................................................................................................................39 8.2 LIFTING DEVICES .................................................................................................................................................40 8.2.1 Inspection Before and After Proof Loading...................................................................................................40 8.3 LIFTED EQUIPMENT .............................................................................................................................................40 8.4 RIGGING...............................................................................................................................................................42 8.4.1 Proof Loading of Rigging used for Offshore Lifting (Boat Lifts)...................................................................42 8.5 REPAIRS AND MODIFICATIONS TO LIFTING EQUIPMENT ......................................................................................42

9

SAFE OPERATING PROCEDURES..................................................................................................................43 9.1 LIFTING OPERATIONS BETWEEN PLATFORMS AND VESSELS ................................................................................43 9.1.1 Planning ........................................................................................................................................................43 9.1.2 Communications ............................................................................................................................................43 9.1.3 Lift Preparation and Handling ......................................................................................................................44 9.2 PERSONNEL TRANSFERS ......................................................................................................................................44 9.2.1 Authority........................................................................................................................................................44 9.2.2 Duties.............................................................................................................................................................44 9.2.3 Suitability of the vessel ..................................................................................................................................45 9.2.4 Weather conditions ........................................................................................................................................46 9.2.5 Communications ............................................................................................................................................46 9.2.6 Safety equipment and rescue procedures.......................................................................................................46 9.2.7 Training .........................................................................................................................................................46

APPENDIX A ..................................................................................................................................................................47 REFERENCE DOCUMENTS......................................................................................................................................47 APPENDIX B...................................................................................................................................................................51 DEFINITIONS .............................................................................................................................................................51 APPENDIX C ..................................................................................................................................................................57 OFFSHORE WIRE ROPE AND CHAIN SLINGS......................................................................................................57 APPENDIX D ..................................................................................................................................................................65 DYNAMIC AMPLIFICATION FACTOR...................................................................................................................65 APPENDIX E...................................................................................................................................................................67 CONTAINER MARKING EXAMPLE .......................................................................................................................67 APPENDIX F...................................................................................................................................................................73 INSPECTION & TESTING REQUIREMENTS..........................................................................................................73 APPENDIX G ..................................................................................................................................................................77

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APPEA Guidelines for Lifting Equipment GUIDE TO AUSTRALIAN AND INTERNATIONAL STANDARDS......................................................................77 APPENDIX H ..................................................................................................................................................................83 GUIDELINES FOR THE PHASEOUT OF ISO SHIPPING CONTAINERS ............................................................83 APPENDIX I....................................................................................................................................................................95 GUIDELINES FOR THE INSPECTION, TESTING AND MARKING OF OFFSHORE CONTAINERS ..............95

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Guidelines for Lifting Equipment

1 INTRODUCTION 1.1

Purpose and Scope

To provide operators, contractors and vendors working in the offshore petroleum industry clear and consistent guidance on the expected standards for design, manufacture, supply and use of lifting equipment. These guidelines are intended to ensure safe lifting operations, thereby minimising risks to personnel and assets. These guidelines apply to “Lifting Equipment” used on and in the following offshore exploration and production facilities and onshore loading facilities, e.g.: • Platforms •

Floating production units

•

Floating production, storage and offloading (FPSO) facilities

•

Mobile offshore drilling units (MODUs)

•

Supply vessels

•

Construction vessels

•

Diving support vessels

•

Seismic vessels

•

Buoys

•

Onshore loading facilities and supply bases

These guidelines do not apply to: • Pipe laying activities •

Specialised wireline operations (i.e.: winches, wireline units, etc)

•

Specialised drilling rig equipment (i.e.: draw-works assembly, travelling blocks, drilling swivels, etc)

•

Heavy lift activities from construction barges

•

Helicopter external lifting

Most of the “Lifting Equipment” used in drilling related operations are addressed in relevant API standards or IADC guidelines.

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APPEA

1.2

Guidelines for Lifting Equipment

Lifting Equipment Terminology

LIFTING EQUIPMENT

LIFTING GEAR

LIFTING DEVICES

LIFTED

RIGGING

EQUIPMENT

Cranes as per AS 1418

Bulk liquid tanks

Wire ropes

(Mobile crane, Tower crane,

Open freight containers

Wire rope slings

Overhead crane, Hoist)

Closed freight containers

Chain Slings

Chain Block

Mini containers

Cherry Picker

Pallets

Flat synthetic webbing slings

Davit

Open top bins

Wire coil flat slings

Forklift

Skips

Polyester round slings

In-situ lifting beam

Baskets

Shackles

Jack

Gas cylinder racks

Hooks

Lever Hoist

Spreader frames

Clamps

Loading arm

Equipment skids

Rings

Monorail.

Long stock container

Swivels

Padeyes Section

Modules

Hammer locks

Trolley

Padeyes Section Lifting points & supporting members of subsea manifolds, christmas trees & subsea valves Lifting points and supporting members of machinery (skids, valves etc)

Sockets

Winch

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1.3

Guidelines for Lifting Equipment

Relationship with Regulations

The majority of Australian legislation covering safety critical equipment such as “Lifting Equipment” is now objective based. This includes the Petroleum (Submerged Lands) (Management of Safety on Offshore Facilities) Regulations 1996 and regulations issued under the various State and Federal Safety and Occupational Health legislation. As such, these guidelines are structured in such a way as to provide guidance to the offshore petroleum industry on “good industry practice”. These guidelines are not to be interpreted as industry “best practice” or minimum standards. The onus of demonstrating that risks have been reduced to as low as reasonably practicable remains with the individual operator or contractor. Offshore petroleum exploration and development in Australia comes under the jurisdiction of the Commonwealth and State or Territory Petroleum (Submerged Lands) Acts. Depending on the lease location, regulations under the Act may be directly administered by the State or Territory or administered by the State or Territory on behalf of the Commonwealth (as a Designated Authority). For offshore operations supply vessels, work boats, offtake tankers, etc, come under the Navigation Act and the detailed Marine Orders referenced within the Act. Similarly when MODUs, FPSO’s, FPU’s, construction barges enter Australian waters they fall under the Navigation Act. When they are moored at drill site they fall under the P(SL)A in addition to the Navigation Act, but immediately on leaving the mooring they revert back to the Navigation Act. Loading and unloading operations at offshore facilities are governed by the P(SL)A which is administered by the relevant state or territory department. Operators attention is also drawn to the AMSA publication “Australian Offshore Vessels – Code of Safe Working Practice”. To demonstrate compliance with the P(SL) Management of Safety Regulations, operators must ensure they have an effective integrated Safety Management System (SMS) in place that identifies, assesses, eliminates and/or manages risk to as low as reasonably practicable.

1.4

Management System

It is expected that, as a minimum, organisations using these guidelines would have in place a formal “Lifting Equipment Management System”. This management system would as a minimum demonstrate how the organisation controls: • Responsibilities for key personnel; •

Registration and trace-ability of “Lifting Equipment” within its control or use;

•

Design, fabrication and supply of “Lifting Equipment”;

•

Inspection and maintenance of “Lifting Equipment” under its control;

•

Safe use of “Lifting Equipment”;

•

Training and competencies of personnel ;

•

Contractor or third party owned “Lifting Equipment”;

•

Auditing of this management system.

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Guidelines for Lifting Equipment

2 COMPETENCY STANDARDS 2.1

Management Responsibilities

It is the responsibility of management to ensure that personnel operating “Lifting Equipment” have the required competencies and are familiar with specific “Lifting Equipment” and work practices used at each facility. This may include the following: • Awareness of relevant codes, standards and guidelines;

2.2

•

Awareness of relevant competency standards;

•

Knowledge of “Lifting Equipment” used on the facility;

•

Lift planning procedures;

•

Requirements for pre-use equipment checks;

•

Requirements for moving loads around the facility;

•

Routine inspection and maintenance requirements;

•

Procedures for loading and unloading supply vessels;

•

Procedures for personnel transfer operations.

Competence of Crane and Forklift Operators, Riggers and Doggers

Crane and fork lift operators, riggers and doggers working within Australia and/or Australian waters are required to hold a certificate of competency issued by either a recognised State Authority or a National Licence issued under the “National Occupational Health and Safety Certification Standard for Users and Operators of Industrial Equipment” (Note: The referenced publication, NOHSC:1006-1992, is available from the National Occupational Health and Safety Commission). Such personnel shall be familiar and competent with facility specific “Lifting Equipment” and work practices.

2.3

Maintainers of Lifting Equipment

Management should ensure that maintenance of “Lifting Equipment” is carried out by suitably qualified and competent personnel, who have knowledge of the following areas: • Awareness of the relevant standards and regulations;

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•

Any site specific requirements and procedures;

•

Maintenance requirements on all types of “Lifting Equipment” to be maintained;

•

Inspection frequency requirements;

•

Detailed inspections requirements for all “Lifting Equipment”; August 1999

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2.4

Guidelines for Lifting Equipment

•

Discard criteria;

•

Disposal processes for failed equipment.

Inspectors of Lifting Equipment

2.4.1 Visual check Competent persons, holding a certificate of competency relevant to the type of equipment, are to carry out a visual check each time the equipment is used.

2.4.2 Lifting Equipment Inspection Bodies A “certified visual inspection” is a more detailed inspection than a visual check carried out on a periodic frequency, the results of which are documented and recorded in the facility “Lifting Equipment” Register. Certified visual inspection shall be conducted by either one of the following: •

Classification Societies with industry accepted inspection standards for “Lifting Equipment.” (e.g. DNV) OR

•

A “body” holding NATA Inspection accreditation for in-service inspection of “Lifting Equipment” to these guidelines.

Inspection of “Lifting Equipment” should be carried out against clearly documented inspection procedures, which include equipment rejection criteria, by suitably qualified and competent personnel as recognised by the above authorities. Refer to section 8 and Appendix I for further details of the certified visual inspection. All inspection reports should bear the endorsement stamp of the appropriate NDT accrediting body. 2.5

Non Destructive Testing (NDT) Laboratories

During initial fabrication, repairs and modifications as well as part of the periodic inspection process, NDT inspection of “Lifting Equipment” shall be conducted by either one of the following: •

Classification Societies with industry accepted laboratory accreditation for NDT testing of “Lifting Equipment.” (e.g. DNV) OR

•

A “body” holding NATA laboratory accreditation for in-service inspection of Offshore “Lifting Equipment” to these guidelines.

All NDT reports should bear the endorsement stamp of the appropriate NDT accrediting body.

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Guidelines for Lifting Equipment

2.5.1 Proof Load Testing Laboratories Proof load testing laboratories shall hold accreditation to these guidelines for the relevant class of proof load testing. Proof load testing of “Lifting Equipment” shall be conducted by one of the following bodies: •

Classification Societies with industry accepted proof load standards for “Lifting Equipment.” (eg. DNV) OR

•

A “body” holding NATA laboratory accreditation for in-service proof loading of “Lifting Equipment” to these guidelines.

All proof load testing reports should bear the endorsement stamp of the appropriate proof load testing accrediting body. Accreditation should be reviewed to ensure that it covers the equipment to be tested.

2.6

Designers of Lifting Gear

Management should ensure that the designers of “Lifting Gear” are qualified engineers experienced in offshore lifting and that the design is also verified by an independent qualified engineer (i.e. an engineer who has had no part in the original design). It is expected that the design or verification of “Lifting Gear” will be conducted by either: •

Classification societies with accepted design standards for “Lifting Gear” (eg. DNV). OR

•

A “body” holding NATA inspection accreditation for design verification of “Lifting Gear” to these guidelines.

All design documentation should bear the endorsement stamp of the appropriate design verification accrediting body. Refers to Sections 5.1, 5.3, 5.7.3, 5.8, 5.9 and 5.14.

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Guidelines for Lifting Equipment

3 REGISTERS OF LIFTING EQUIPMENT 3.1

Introduction

Each facility shall maintain a register or registers of all types of “Lifting Equipment” used on site and owned by the operator. Likewise, contractors should maintain a register of their “Lifting Equipment” on each facility. This is a statutory requirement for vessels operating under the Navigation Act. All suppliers of “Lifting Equipment” that is leased to offshore operators and/or contractors shall also maintain a register of all such equipment.

3.2

Lifting Equipment Register

A register, as a minimum, shall contain an inventory of all “Lifting Equipment” present on or at the facility (this is equipment that effectively “belongs” to the facility). The register of “Lifting Equipment” may be in an electronic format or in the form of a card or other paper register system. Register systems should identify the location of all hard copy records of design verifications, inspection certificates, maintenance records, test certificates, etc. Because of differing recording requirements the register should be split into equipment types or Classes, e.g. “Lifting Devices” (cranes, padeyes, etc), “Lifted Equipment” (containers, baskets, etc) and Rigging (slings, shackles, etc).

3.3

Lifting Equipment Register Contents

The register is expected to contain the following entries as applicable for each item of equipment: • A full description of the equipment; •

The safe working load (SWL) of the item or maximum gross weight (MGW) as applicable;

•

The unique identification or tag number for the item;

•

Manufacturer’s serial numbers;

•

Batch number of the item if applicable;

•

The location (or reference to the drawing showing the location - particularly for padeyes) of the item. The usage of the item (e.g. stores unloading, engine room general lifting etc);

•

Date of entry onto the register;

•

Whether a Certificate of Conformity is required for the item;

•

A copy of the Certificate of Conformity, or number of, approval bodies and date of issue;

•

The location of the design verification certificate and documentation;

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Guidelines for Lifting Equipment

•

Whether a certificate of inspection is required;

•

The inspection certificate number, issuing body and date of issue;

•

For cranes, winches, containers, special “Lifting Equipment”, padeyes etc, the design and fabrication codes and the location of the manufacturer data report;

•

For “Lifting Gear”, the national standard to which the item was purchased;

•

Re-inspection interval;

•

Reference to the approved maintenance and operating manual for the item.

These entries shall be supported (as applicable) with the following traceable hard copy records as issued by a body holding accreditation to these guidelines with NATA or a Classification Society with industry accepted design and inspection standards for “Lifting Equipment”: • Certificate of design verification; •

Current certificate of inspection;

•

Type test certificate;

•

Manufacturers test certificate/s (for “Lifted Equipment”);

•

The maintenance and inspection records (including the past inspection reports for visual inspections, calibrations, adjustments, change out of equipment etc);

•

Proof load test and NDT reports.

Where applicable, these entries shall be supported with traceable hard copy records of the following: • Original manufacturer’s data report; •

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Original design calculations.

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Guidelines for Lifting Equipment

4 DESIGN OF OFFSHORE LIFTING DEVICES 4.1

Introduction and Scope

This section provides guidance on “Lifting Devices”, as defined in Section 1.2, and their associated equipment installed or erected on offshore facilities. These guidelines do not apply to cranes with a maximum Safe Working Load over 200 tonnes. 4.2

Design, Manufacture and Installation (General)

“Lifting Devices” should be suitable for their intended purpose and should be of sound construction, suitable material, of adequate strength and free from patent defects. Equipment should be designed with due regard to the intended use with or near other equipment and for safe use under known operating conditions, including any overload conditions which may be anticipated, (i.e. proof load testing, etc.). Where relevant, the equipment should have efficient control systems, guards, fences and shields. Particular consideration should be given to the effectiveness of mountings on all “Lifting Devices”. The design of “Lifting Devices” should be consistent in its approach with that used to design the “Lifted Equipment” and Rigging, (i.e. a device designed to API codes, with rigging to DNV codes and equipment to AS codes, may provide an inconsistent application of factors of safety and failure load paths through the lift). An independent competent person, as recognised by NATA, or a Classification Society, with industry accepted design, testing and inspection standards for “Lifting Equipment”, should be involved when any of the following actions are being considered: • Initial design;

4.3

•

Modifications to any “Lifting Equipment”;

•

Repairs to safety-critical elements of “Lifting equipment”;

•

Testing or overload testing of “Lifting Equipment” after repair or modification.

Cranes

The detailed design of offshore cranes is beyond the scope of this document and is normally completed by the specialist crane supplier. Common acceptable standards specified for offshore cranes are: • API Spec 2C Specification for Offshore Cranes; •

Lloyds Code for Lifting Appliances in a Marine Environment, together with BS2573 Rules for the Design of Cranes;

•

AS1418 Crane Code.

In order to minimise risk, an operational risk assessment should be conducted based on an analysis of failure modes and their consequences. The safety of lifting operations, with regard to personnel on or near the facility, must be considered. ____________________________________________________________________________ August 1999

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Guidelines for Lifting Equipment

Additional requirements to be considered for the crane specification, depending on the principal guidance used may, include: • Crane Operating Limitations; •

Controls and Instrumentation;

•

Power;

•

Primary Structural Components and Maintenance Access ;

•

Slewing Rings;

•

Kingpost Cranes;

•

Operators' Compartments;

•

Winding Gear;

•

Rope Anchorage and Terminations;

•

Wire Rope (hoisting and booming);

•

Wire Rope Grips and Clamps;

•

Wire Rope Examination and Discard;

•

Hooks;

•

Crane Hook Blocks;

•

Ram Luff Cranes;

•

Slew ring failure;

•

Fatigue requirements;

•

Documentation.

The following tables give an example of minimum requirements for the specification of cranes to a supplier.

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Guidelines for Lifting Equipment

4.3.1 Crane configuration Table 4.3.1. Crane Configuration Specification Crane type A-frame / ram luffing / telescopic / king post Boom type closed box / lattice boom Boom length m Auxiliary hoist required Yes/No Prime mover diesel / electric motor Preferred suppliers: Transmission Hydraulic Rotation continuous 360° Machinery house Yes/No weather / sound proof enclosure Control cabin / location Yes/No crane / remote If crane : left / right side (looking towards boom tip) Floodlights (Total number, location) Gas / smoke detector fixing arrangements required

Yes/No

Power outlet sockets Collector rings Total number (for status lights, telephone etc.)

type:

spec:

Anti-condensation heaters required

Yes / No / Manufacturer to propose

4.3.2 Performance criteria (Minimum Requirements) Table 4.3.2. Crane Performance Criteria Specification Max. dynamic lift kg at (at conditions given in Appendix 2 section 3) Max. static lift kg at Max. auxiliary lift Main hook speed (minimum) Auxiliary hook speed (minimum) Personnel lift required

kg at m/min m/min Yes/No

Installed platform design life

Years

Total duty cycles Surface temperature limitation

°C

m. minimum working radius m. minimum working radius m. minimum working radius

kg

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4.3.3 Environmental criteria Table 4.3.3. Environmental Criteria Specification Ambient temperature max./min. °C/ °C Design temperature max./min. °C/ °C Humidity % relative/absolute Atmosphere Saline / Location Surface wind m/s maximum instantaneous gust m/s Wave height (significant) Wave period Excessive temperature exposure

Snow and ice conditions Operating – thickness Stowed – thickness Hazardous area classification As per IP Model Code of Safe Practice, Part 15 Diesel exhaust emission control standard

m seconds flue gas exhaust °C flare °C boom °C upper structure °C Yes/No mm mm boom: power unit:

cab: crane:

4.3.4 Utilities available Table 4.3.4. Utilities Specification Diesel fuel Yes/No Electricity

AC (power) AC (control) DC Emergency / uninterrupted

Air supply (instrument quality) Air supply (plant quality) Potable water (limited to top-up use only)

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Grade: V V V Yes/No V

φ φ

Hz Hz A AC/DC φ bar (ga) m3/min bar (ga) m3/min Yes/No

Hz

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4.4

Guidelines for Lifting Equipment

Mobile Cranes

Mobile cranes offshore should be classed as temporary mobile equipment and should only be used for the purpose agreed by the operating company, the owner and a competent person. Where mobile cranes are used for operations subject to sea-state induced dynamics, they should generally comply with the recommendations of Section 3 and the following items should also be considered: • Permissible locations (i.e. area of safe operation) including adequacy of supporting structure;

4.5

•

Barriers to prevent the crane colliding with other parts of the installation, or toppling overboard;

•

Safe limits of operation on floating installations and any associated means of stowing or securing the crane in adverse weather conditions;

•

Means of securing while lifting from supply vessels or any other sea-state operation;

•

Dynamic effects and de-rating for sea state operations;

•

Inspection of safety-critical structural and mechanical components.

•

Details should be included in an appropriate manual addressing the use of the mobile crane in offshore operations.

Gantry Cranes, Lifting Beams and Lifting Aids

Gantry cranes, lifting beams, lifting frames, spreaders, etc. should be designed, constructed and tested in accordance with a recognised standard, supplemented with any specific conditions of use (such as operational sea-state and/or maximum list/trim and roll/pitch). Any such conditions of use should be made clearly visible to the operator of the crane and also be stated in an appropriate manual for the equipment. Gantry cranes should be fitted with end limit switches and mechanical stops for all travel motions. If travel speeds are sufficiently low to warrant over-travel being arrested by mechanical end stops only, then approval for this mode of operation should be obtained from a competent person.

4.6

Lifting Points

Permanently attached lifting points should be designed to a recognised standard (Appendix G) and be subject to examination and testing in accordance with these guidelines. The design of lifting points such as padeyes, pad-ears, lifting lugs, etc. should incorporate the magnitude, direction and effects of load distribution. The design of the surrounding structure to which lifting points are affixed should allow transmission of the load from the lifting point to the surrounding structure. Adequate clearances should be provided between the lifting point and the connecting device. Lifting points should be free from any detrimental defects caused by oxy-cutting, arc welding, etc. ____________________________________________________________________________ August 1999

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Guidelines for Lifting Equipment

Testing of pad eyes, lifting lugs etc. should be agreed with a competent person and carried out to comply with the current requirements.

4.7

Hoisting Equipment (Manually Operated)

Manually operated hoisting equipment should be designed, manufactured, tested and marked in accordance with recognised codes and standards (Appendix G). Pawls for the ratchet mechanism should either be spring-loaded or engagement with the ratchet ensured by other positive means. Engagement should not depend solely on gravity or a tension spring alone. Hand chains should be smooth and free from rough areas. The effort required to operate manual hoisting equipment should not exceed that which one person can comfortably exert from a standing position. If manually operated hoisting equipment is to be continually used in an area where a flammable gas could be present, the equipment should be made spark proof and be so stated on the identification plate. Under no circumstances should powered means be used to raise loads with a manually operated hoist. A restriction to this effect should be displayed on the hoist or, if this is not practicable, a suitable notice should be contained in the operation/instruction manual for the equipment.

4.8

Man-Riding Equipment

4.8.1 Cranes Used for Man Riding Operations The following guidance applies to cranes used for personnel lifting. Outline guidance on procedures for transfer of personnel by basket is provided in Section 9.2. Free fall operations of the hoist or boom motion are not permitted. Winding gear should be equipped with a brake, mechanically operable under all load conditions. The design braking force should be at least 120% of the braking force required to support the stipulated test overload. Dynamic braking effects due to hydraulic transmission systems should not be considered as a mechanical brake when using cranes for man-riding operations. The brake should be automatically applied when the drive is in the "off" or the "neutral" position. Any change-speed gearbox should be of constant mesh type whereby it should not be possible to change the gear ratio while there is any load on the winch. Clutches or other means of disengaging the drive train are prohibited for this type of operation. Brake action should be progressive in order to avoid sudden dynamic shock. The brake should be applied automatically upon failure of the power supply to the motor and/or control device. A secondary brake should be fitted and be operable by the driver in an emergency situation involving man-riding operations and arrest all crane motions. The secondary brake should be applied directly at the drum and not through gear boxes, gear trains etc. The brake need only be of a size sufficient for arresting the loading of persons and the basket, together with some dynamic allowance. An emergency stop should be fitted that can be operated by the driver in an emergency situation. Operation of the emergency stop should arrest all crane motions by the actuation of the motion brakes. In the event of failure of the prime mover to re-start, it should be possible to recover the load by manual means. Page 18

August 1999

APPEA

Guidelines for Lifting Equipment

Cranes which are suitable for man-riding duties should be clearly marked "SUITABLE FOR MANRIDING DUTIES" at the crane operator's control location.

4.8.2 Tugger and Man Riding Winches All tugger and man riding winches should be designed: • with a winch operating lever which should automatically return to neutral on release in any operating position; •

with automatic brakes which will apply whenever the operating lever is returned to neutral or on loss of power;

•

without a clutch capable of disengaging the drive.

Winches to be used for man-riding duties should additionally be designed: • with a secondary brake to prevent the load from falling in the event of failure of the automatic brake; •

with devices to prevent the winch rope from over- riding or under-riding;

•

with provision for spooling the wire on the drum to prevent wear or entanglement;

•

to be capable of lowering the load in the event of an emergency, such as loss of power;

•

with a brake holding which is less than the minimum breaking load of the rope and more than the maximum line pull of the winch in the man-riding mode of operation; if a high load is applied to the winch, the brake must render before the breaking load of the rope is reached:

•

with a suitable guard over the drum to provide protection to the operator in the event of rope breakage. Such a guard should not inhibit the ability of the operator to see the spooling action of the rope on the drum.

All man-riding winches shall be clearly labeled "SUITABLE FOR MAN -RIDING".

4.9

Surveys and Inspection

In determining the scope and extent of surveys, due account should be taken of applicable legislative requirements and the various recommendations on examinations or tests given in this section, together with the results of any such examinations or tests previously carried out. For cranes, at least one full load test should be witnessed by a competent person. Where examinations or tests are proposed for the purpose of or consideration with regard to crane certification, the competent person should be consulted in advance with a view to agreeing the basis for their acceptance and that the results of the examinations or tests are recorded and reported in a manner that meets this purpose. Surveys may need to be brought forward if the competent person is of the opinion that a crane has experienced excessive loading or overloading. ____________________________________________________________________________ August 1999

Page 19

APPEA

Guidelines for Lifting Equipment

4.10 Documentation An appropriate operations manual should contain particulars of the relevant “Lifting Devices”. As a minimum, the contents should include general arrangements for the machinery and equipment, wiring and piping diagrams where appropriate, and instructions for the operation of the devices. The manual should contain operating limits, checks and test procedures, which are required to be carried out to ensure safe operation of the equipment. Any special instruction for safe operation of appliances, such as those for man-riding winches in section 4.8, should be noted. All “Lifting Devices” should have an appropriate maintenance manual which gives details of servicing, repair, essential spares holdings and any special tools required for maintenance purposes. All “Lifting Devices” should be provided with a test certificate containing the following information: • Type description; •

Model description;

•

Serial number;

•

Description;

•

Classification of mechanism (where powered);

•

Rated capacity of hoisting or hauling;

•

Test load applied;

•

Name and address of manufacturer;

•

Name and status of signatory;

•

Date of issue of certificate.

Page 20

August 1999

APPEA

Guidelines for Lifting Equipment

5 DESIGN OF OFFSHORE LIFTING GEAR 5.1

Introduction

This section of the guidelines covers the general requirements for the design of “Lifting Gear” as distinct from “Lifting Devices” such as cranes, winches, etc. Guidelines for the design of “Lifting Devices” for offshore use are presented in Section 4. Rigging can be selected by equipment users from manufacturers handbooks provided the factors of safety given in section 5.4 below are met and the load does not exceed approximately 25 tonnes (the arbitrarily selected limit for Engineering Lifts). It is anticipated that in due course rigging suppliers will have catalogues available of “Lifting Gear” suitable for offshore lifting. Where offshore loads exceed 25 tonnes an engineered lift should be considered [refer to AS 1666.2 (1995), section 9c]. In these cases design of all “Lifting Gear” is expected to be performed by qualified engineers experienced in offshore lifting. With respect to the design of “Lifted Equipment” regardless of the lifted load, it is expected that the design will be performed by “qualified engineers experienced in offshore lifting”. Refer to clause 2.6 for competency requirements. 5.2

Design Approach for Engineered Lifts

For the design of “Lifting Gear” to be used for an engineered lift the design engineer’s tasks should include but not be limited to: • Ensuring that design criteria are acceptable to the user of the “Lifting Equipment”; • Addressing all relevant design conditions including transport, installation, loading & unloading, operation, temperature and fatigue considerations. The design should consider but not be limited to: • Weight uncertainty; • Weight growth potential; • Uncertainty in COG; • Dynamic amplification (DAF) ; • Diagonalling effects; • Local eccentricities arising from padeye connection details; • Drag loads on equipment to be lifted in water; • Load Radius Chart for the “Lifting Device” (Crane); • Wave height and period. For engineered lifts where the rigging for a particular load has been specifically designed the rigging requirements shall be noted in a work order or preferably attached to the load (eg, a plate which reads "For Rigging requirement refer to Drg. No. ... ").

____________________________________________________________________________ August 1999

Page 21

APPEA

5.3

Guidelines for Lifting Equipment

Over Chart Lifts

For "over chart" lifts (i.e. for lifts that exceed the load radius curves for the crane in question) a lift analysis shall be carried out in close liaison with the “Lifting Equipment” manufacturer, the installation contractor and the operator. The Dynamic Amplification Factor (DAF) may be reduced by limiting the sea state in which the lift can be carried out. In the case of deck or onshore lifts the hoisting speed can be reduced to limit the dynamic effects. These limitations shall be clearly shown on the design drawings, which are to be duly signed "Accepted for Lift" by the engineer accepting overall responsibility. For offshore lifts, codes such as "DNV Marine Operations Part 2 Chapter 5" and "Lloyd’s Code for Lifting Appliances in a Marine Environment" offer guidance. 5.4

Design of Rigging

These guidelines vary the required factors of safety for rigging depending on whether the rigging is to be used offshore or onshore. The dynamic factors of safety are based on findings of the field study “Investigation of Dynamic Amplification Effects During Offshore Lifting” Reference 65. Non-dynamic factors of safety are addressed in a discussion paper on “Factors of Safety for Lifting Slings used in Offshore Supply Boat Operations” Reference 64. The following equation is based on a similar equation given in AS 1666.2 (1995) section 9 and includes a material factor (Rm) such that it can be used universally. The SWL of a sling assembly shall be calculated from the equation: SWL = (Rc Rm Rt Ro) x P 4 x 9.81

Equation

1.

Where SWL = P =

Safe Working Load of the sling assembly (in tonnes) Minimum Breaking Force for the individual rope (kN), chain or webbing which comprises the assembly

Rc

=

Factor for Sling Assembly Configuration

(refer Table 1 AS1666.2 (1995))

Rm

=

Material Factor

(refer Table 5.4.1 )

Rt

=

Termination Factor

(refer Table 5.4.2 )

Ro

=

Operational Factor

(refer Table 5.4.3 )

Table 5.4.1

Material Factor (Rm) Sling Type

Page 22

Rm

Chain and Lifting Components (Ref AS3776)

1.0

Wire Rope

1.0

Flat Synthetic Webbing Slings

.57

Round Synthetic Slings

.57

Shackles (Grades S&T Only)

0.80

August 1999

APPEA

Guidelines for Lifting Equipment

Table 5.4.2

Termination Factor (Rt) Sling Type

Rt

Chain and Lifting Components (Ref AS3776) Wire Rope

1.0 1.0 - 0.8 (refer Table 2 AS 1666.2 1995)

Flat Webbing

.875

Round Slings

1.0

Shackles

1.0

Table 5.4.3

Operational Factor (Ro) Type of Operation Onshore or Platform Lift

(Ro) 1.0

Application -

0.69

6 tonnes

6 tonnes < SWL ≤ 10 tonnes

0.69-0.81

SWL tonnes

10 tonnes < SWL ≤ 25 tonnes

0.81-0.92

SWL tonnes

0.40

-

Offshore Lift (Hs max 3.0m) SWL ≤ 6 tonnes

Personnel Lift Note:

1. 2. 3.

For SWL > 6 tonnes, Ro may be obtained by linear interpolation between the parameters specified. Where the lift weight is not measured, the uncertainty of the lift weight shall be considered. Where the Factor of Safety for wire ropes, predicted herein, is less than the Factor of Safety as specified in AS1666(1976) the greater value shall be applied.

The Safe Working Load (SWL) can also be expressed in terms of a Factor of Safety (FoS): SWL =

P FoS Rc

Where FoS

=

4/(Rm Rt Ro)

Equation.

2

Where the Factor of Safety as specified in Equation 2 is less than the Factor of Safety as specified in AS1666(1976) for wire rope, the greater value shall be applied. Equation 2 is consistant with the explicit application of termination efficiency where AS1666(1976) is based on the poorest performing termination. Although equation 2 would allow a minimum Factor of Safety for a conventional ferrule secured wire rope sling of 4.21 this guideline is adopting a minimum Factor of Safety of 5 as recommended in AS1666(1976). It should be noted that the for a similar sling the Factor of Safety as specified in AS1666(1995) would be 5.26 for which the increase in conservatism from AS1666(1976) does not appear to have any justifiable technical basis. For further discussion on this issue refer to Reference 64. The Factor of Safety for chains and wire rope are provided as a function of SWL in Figure 1 and Figure 2 respectively. Table 5.4.4 lists recommended Factors of Safety for commonly used slings in offshore and onshore operations for direct loaded lifting arrangements. Values for other types of operations may be determined by substituting the appropriate values of Rm, Rt and Ro in Equation 2. ____________________________________________________________________________ August 1999

Page 23

APPEA

Guidelines for Lifting Equipment

Table 5.4.4

Recommended Factors of Safety for Commonly Used Slings

Type of Operation

Ro

Onshore or Platform lift

Chain Sling Rt= 1.0 Rm = 1.0

Wire Rope Rt=0.95, Rm =1.00 5, (Theoretical value = 4.21)

Flat Webbing Rt=.875 Rm=.57

Round Webbing Rt=1.0 Rm=.57

8

7

1.00

4

SWL 20t GW + 5t GW: < 3t, GW x 2 GW: 3-12t GW + 3t GW: 12-20t GW x 1.25 GW: > 20t GW + 5t

GW x 2.5 over 4 lifting points and GW x 1.5 over 2 lifting points

GW x 3.0

GW x 4.0

GW x 2.5 over 4 lifting points and GW x 1.5 over 2 lifting points

APPEA

Guidelines for Lifting Equipment

TABLE F.3 INSPECTION AND TESTING REQUIREMENTS FOR RIGGING Notes: 1. Offshore containers shall have specifically designed lifting sets, which shall not be removed from the container except for replacement of the lifting set or for examination of the container. 2. For Safety Factors for Rigging Equipment used in Offshore Lifting Operations refer to section 5.4. 3. Minimum chain diameter to be 10mm. For containers with Gross Weight more than 3500kg, the minimum chain diameter must be 13mm. 4. Min. Wire Rope diameter to be 13mm. For containers with Gross Weight more than 3500kg, the minimum wire rope diameter must be 20mm. PROOF LOAD TEST

CERTIFIED ITEM

REFERENCE

VISUAL

NDT FREQUENCY

INSPECTION

ONSHORE LOAD

Loose Rigging (Includes all types wire and synthetic ropes, chains, links, shackles, swivels, rings, sockets, hammerlocks, etc)

APPEA

Lifting Sets (Includes wire rope and chain sets, complete with all associated accessories)

APPEA

Crane Hooks

APPEA

Page 76

•

Not Required

•

3 monthly visual inspections

•

Colour coding

•

Subject to visual inspection

•

Initial Certification Test

•

Subject to company program.

Subject to visual inspection.

•

Initial Certification Test

•

Offshore – Every 6 years as part of the “Lifted Equipment” Proof Load Test.

•

Every 2 years

•

Initial Certification Test

•

Subject to Visual Inspection

Type test to destruction by Manufacturer

OFFSHORE LOAD Type test to destruction by Manufacturer

Visual inspection each time before use. 1 year as part of the container inspection.

1 year

August 1999

It will be necessary to remove the sling set and test according to Australian Standards

50% x Rm x Rt x MBL

Refer to Manufacturer

Refer to Manufacture

APPEA

Guidelines for Lifting Equipment

APPENDIX G

GUIDE TO AUSTRALIAN AND INTERNATIONAL STANDARDS

August 1999

Page 77

APPEA

Guidelines for Lifting Equipment

Table G1- Guide to Australian and International Standards Note: This table is intended as a guide only. In many cases, requirements of International standards will be less onerous than Australian standards. Requirements less onerous than Australian standards are not recommended to be adopted without specific Operator approval.

Aust/NZ No

Australian/New Zealand Title

ANSI Standard

British Standard BS 5555 BS 464 BS 3226 BS 6072

AS ISO-1000 AS 1138

The International System of Units Thimbles for Wire Rope

-

AS 1171

-

AS 1353

Non-Destructive Testing Magnetic Particle Testing of Ferromagnetic Products, Components and Structures Flat Synthetic Webbing Slings

-

AS 1380

Fibre Rope Slings

-

AS 1418

Cranes (Including Hoists & Winches)

AS 1438

Wire - Coil Flat Slings

AS 1504

Fibre Rope - Three Strand Hawser Laid Structural Steel Welding

AS/NZS 1554 AS 1657

AS 1664

Page 78

Fixed Platforms, Walkways, Stairways and Ladders - Design, Construction and Installation Aluminium Structures Code

-

BS 3481 BS 5053 BS 2052 BS 4921 BS 7648 BS 327 BS 357 BS 466 BS 1757 BS 2452 BS 2573 BS 2799 BS MA41 BS MA79 -

-

DNV Std Rules for Marine Operations Part 2 Chap 5 -

ISO Std ISO 1000 -

-

-

-

-

Rules for Certification of Lifting Appliances

-

-

-

-

-

-

AWS D1.1

BS 4870

-

-

A1264.1

BS 4592 BS 5395

-

-

AWS D1.2

BS 8118

-

-

ASME B30 API RP2D Spec 2C

August 1999

APPEA

Aust/NZ No

Guidelines for Lifting Equipment

Australian/New Zealand Title

ANSI Standard

British Standard

DNV Std

ISO Std

BS CP118 AS 1666

Wire Rope Slings

ASME B30.9

BS 1290

AS 2089

Sheave Blocks of Maximum Lift 60 Tonne

-

AWS C3.8

AS 2317

Non-Destructive Testing for Ultrasonic Testing of Fusion Welded Joints in Carbon & Low Alloy Steel Collared Eyebolts

BS 4018 BS 4344 BS 4536 BS MA47 BS EN 1714

AS 2207

ASME B18.15

BS 4278

AS 2318

Swivels for Hoists

-

-

AS 2319

Rigging Screws and Turnbuckles

-

BS 4429

AS 2321

Short Link Chain for Lifting Purposes (Non Calibrated)

ASME B29

AS 2550 (1982)

Cranes – Safe Use

ASME B30

BS 3113 BS 3458 BSEN 818-1 BS 6304 -

AS 2741

Shackles

AS 2759

Steel Wire Rope - Application Guide

AS 3569

Steel Wire Ropes

AS/NZS 3678

Structural Steel – Hot Rolled Plates, Floor Plates and Slabs Structural Steel – Part 1 : Hot Rolled Bars and Sections Structural Steel – Part 2 : Welded I Sections

AS/NZS 3679.1 AS/NZS 3679.2

August 1999

API RP9B Spec 9A

SAE J763 SAE J1392 SAE J1442 -

BS 3551 BS 6994 BS 6210 BS 6570 BS 183 BS 302 BS 525 BS 7613

Rules for Marine Operations Part 2 Chap 5 Rules for Marine Operations Part 2 Chap 5

-

-

-

-

-

Rules for Marine Operations Part 2 Chap 5 -

-

-

-

Rules for Marine Operations Part 2 Chap 5

-

Rules for Certification of Lifting Appliances Rules for Marine Operations Part 2 Chap 5 -

-

Rules for Marine Operations Part 2 Chap 5

ISO 3578

-

-

BSEN 10210-2

-

-

-

-

-

Page 79

APPEA

Aust/NZ No

Guidelines for Lifting Equipment

Australian/New Zealand Title

AS 3775

Chain Slings – Grade T

AS 3776

Lifting Components for Grade T Chain Slings Shank Hooks and Large Eye Hooks Maximum 25 Tonne Mechanical Equipment - Steelwork

AS 3777 AS 3990

ANSI Standard

British Standard

ASME B29 -

BS 2902 BS 6968 -

ASME B30.10

BS 2903

AISC

AS 4100

Flat Pallets for Materials Handling (1100mm x 1100mm suitable for use in ISO Series 1 Freight Containers) Steel Structures

AS 4142

Fibre Rope

-

AS B291

Lifting Rings & Links

-

BS 5950 BS 7608 DDENV 1993 DDENV 1994 BS 3810 BS 6637 BS M69 BS 5950 BS 7608 DDENV 1993 DDENV 1994 BSEN 698 BSEN 701 BSEN 1251 BS 7648 -

AS/NZS 3711.1

ANSI MH

AS/NZS 3711.4

Freight Containers:- Part 1 Classification, Dimensions & Ratings Freight Containers:- Part 2 – Terminology Freight Containers:- Part 3 - Corner Fittings General Purpose Containers

AS/NZS 3711.5 AS/NZS 3711.6

AS 4048

AS/NZS 3711.2 AS/NZS 3711.3

Page 80

ASME MH

AISC

DNV Std

ISO Std

Rules for Marine Operations Part 2 Chap 5 Rules for Marine Operations Part 2 Chap 5 Rules for Marine Operations Part 2 Chap 5 -

-

-

ISO 445

-

-

Rules for Marine Operations Part 2 Chap 5

-

-

BS 3951

Rules for Marine Operations Part 2 Chap 5 -

ISO 668 Amd.1

ANSI MH

BS 3951

-

ISO 830 Amd.1,Amd.2

ANSI MH

BS 3951

-

ISO 1164 Cor.1

ANSI MH

BS 3951

-

ISO 1496.1 Amd.1

Thermal Containers

ANSI MH

BS 3951

-

ISO 1496.2

Tank Containers

ANSI MH

BS 3951

-

ISO 1496.3

August 1999

APPEA

Aust/NZ No

Guidelines for Lifting Equipment

Australian/New Zealand Title

ANSI Standard

British Standard

DNV Std

ISO Std

AS/NZS 3711.7

Dry Bulk Containers

ANSI MH

BS 3951

-

ISO 1496.4

AS/NZS 3711.8

Platform Containers

ANSI MH

BS 3951

-

ISO 1496.5 Amd.1

AS/NZS 3711.9

Coding, Identification and Marking

ANSI MH

BS 3951

-

ISO 6346 Amd.1

AS/NZS 3711.10

Handling and Securing

ANSI MH

BS 3951

-

ISO 3874 Amd.2

August 1999

Page 81

APPEA

Guidelines for Lifting Equipment

Page 82

August 1999

APPEA

Guidelines for Lifting Equipment - Phase Out of ISO Containers

APPENDIX H

GUIDELINES FOR THE PHASEOUT OF ISO SHIPPING CONTAINERS OFFSHORE

August 1999

Page 83

APPEA

Guidelines for Lifting Equipment - Phase Out of ISO Containers

PREAMBLE

The purpose of this document is to provide a guideline for the inspection and testing of ISO shipping containers used in the offshore oil & gas industry. ISO shipping containers are not designed for use in the offshore industry where dynamic lifting forces apply. These guidelines will remain in force until the target phase out date of 31/12/2000 is reached. Whilst this is an industry target date, individual companies may require that ISO containers be removed from service at an earlier date. In the interim this document will provide guidance for the management of ISO containers including inspection, de-rating and testing requirements. For design and fabrication of replacement containers the requirements of the draft APPEA “Guideline for Lifting Equipment” should be used. The following section is extracted from the referenced document.

August 1999

Page 85

APPEA

Guidelines for Lifting Equipment - Phase Out of ISO Containers

DOCUMENT SCOPE Provision of procedures & guidelines to manage the use of ISO containers used in the offshore industry. The document provides guidelines for the inspection, testing and marking of ISO containers used in the transport of goods to and from offshore locations. The use of the containers is to be managed in accordance with this document. DOCUMENT SOURCE & RECOGNITION

IDENTIFICATION OF “ISO” CONTAINERS

CONTROLLED USE OF ISO CONTAINERS

Much of the information contained within the documents on ISO Containers has been reproduced from Woodside Energy Ltd’s (WEL), King Bay Supply Base, Lifting Equipment Management System. APPEA thank WEL for their contribution in permitting contents of their documents to be reproduced herein.

ISO containers are the containers originally built for international shipping and fitted with ISO Corner fittings and lifted in container ports, from these fittings, with a purpose built spreader frame and special “Twist-locks”. Most are 20ft in length although 10, 30 & 40ft lengths are also available. NOTE: It is possible for purpose built offshore containers to have ISO Corner fittings. This is quite acceptable, provided that these are only used for securing during transport and/or onshore/inshore lifting in accordance with onshore/inshore container lifting guidelines as detailed in AS 3711.10:1993 “Freight Containers – Handling and Securing” and, are not used for offshore lifting.

Containers used in international shipping are controlled by the International Convention for Safe Containers (CSC). When the containers used in international and/or coastal shipping reach the end of their service life, either through condition or a “time life” expiry they are often sold off without current CSC compliance. Any existing CSC compliance plate has no meaning in the offshore industry except for a reference in de-rating the container as detailed within this document. The containers are designed and rated for use in still water ports and not for offshore use where significant dynamic forces occur during lifting operations.

REFERENCE MATERIAL

Page 86

Marine Orders, Part 44, Section 11 International Maritime Organization Circular 613 (to be replaced by Maritime Safety Committee, Circular 860) International Convention for Safe Containers (CSC) IMO, 1982 DNV 2.7-1 Offshore Containers -Certification Notes. AS3711.10 – 1993 - Freight Containers, Handling & Securing APPEA “Guideline For Lifting Equipment.”

August 1999

APPEA

Guidelines for Lifting Equipment - Phase Out of ISO Containers

Typical ISO Container “ISO” corner fitting

ALLOWABLE ISO CONTAINER STYLES & LENGTHS

Closed roof, ISO containers up to 20 ft. in length will be accepted for offshore transportation subject to meeting requirements of this document. Open top style, ISO containers and any ISO container over 20 ft in length will not be accepted for offshore transportation.

MODIFICATIONS TO ISO CONTAINERS

Any ISO container that has been modified from the original CSC design must have engineering calculations to support the continued integrity of the container. Unlike a purpose built offshore container, which is designed to carry full load on primary structure members, ISO containers rely on the integrity of wall panels for primary strength. Such modifications may include: • Addition of extra doorway • Alteration to length

PHASING OUT ISO CONTAINERS FROM OFFSHORE INDUSTRY

Contractors currently utilizing ISO containers are expected to reduce the number in use during the lead up to the phase out date and replace with purpose built offshore shipping containers. Advice regarding standards and guidelines to be followed for new designs will be issued to the Australian offshore oil & gas industry by APPEA in “Guideline for Lifting Equipment ” currently in draft form. An extract from the draft APPEA Guideline is included on Page 2 of this document.

August 1999

Page 87

APPEA

COMMENTARY ON LIFTING POINTS

Guidelines for Lifting Equipment - Phase Out of ISO Containers

• •

Even in a still water port situation, ISO shipping containers cannot be lifted from the ISO Corner fittings by shackles and slings. This applies even when empty. Lifting with spreader frames as used in port situations is not allowed in offshore lifting operations. Refer to clause 2.2 of IMO 613 (referred to in Marine Orders Part 44.)

NOTE: IMO 613 will be replaced by a new Maritime Safety Committee document “Guidelines for the Approval of Offshore Containers Handled in Open Seas.” (MSC Circular 860) This document further emphasises that ISO corner fittings are not to be used for lifting in offshore transport operations. ISO containers used in the offshore industry should have padeyes that are purpose built. Refer to “Padeyes” below.

Shackles in ISO Corner fittings are not permitted.

PADEYE REQUIREMENTS

Page 88

➚ Although not generally required when container is down-rated, lifting with special lifting beams will be allowed during phase out. Must be fitted to padeyes as shown.

The installation of padeyes must be carried out in accordance with good engineering practices. • Design by qualified structural engineer. • Design verification by independent engineer, who has not been involved in the design. • Carry MGW on 2 of four padeyes. • Align to centre of gravity of the load to provide for the angle of the lifting forces to be 45 degrees from the vertical. • Shackle pin hole to be +3mm or, not greater than 4% more than the shackle pin diameter. • Width of padeye to be equal to 75% of the opening of shackle to be fitted. This may be accomplished by fitting bosses to padeye. • Material trace-ability. • Documented welding procedures (To AS1554, AWSD1.1 etc.) • Welder qualification trace-ability. • NDT inspection of all welding associated with padeyes. NOTES: 1. The installation of padeyes MUST have engineering trace-ability. 2. DNV 2.7-1 provides full details of padeye design and material requirements and designers are encouraged to use the DNV document as a guide.

August 1999

APPEA

ALLOWABLE MGW (Maximum Gross Weight)

Guidelines for Lifting Equipment - Phase Out of ISO Containers

ISO Containers used in the offshore industry where significant dynamic forces occur during lifting from supply vessels must be significantly de-rated. Subject to satisfactory inspections as per Page 7, ISO container use, up to the phase out date, will be allowed under the following conditions: • De-rated by multiplying original CSC Maximum Gross Weight (or Mass) x 2 and dividing the figure by 5. E.g. A 24 tonne MGW container x times 2 = 48 tonnes divided by 5 = 9.6 tonnes MGW.

MARKING REQUIREMENTS

All ISO containers, original or modified, shall have: • A stenciled marking beside the CSC data plates indicating “Not Applicable”. The plate should remain to indicate the original MGW that is used in the de-rating formula above. Marking plates are required for: • Operational Marking Plate (Tare, Nett & Gross) • Test Plate (date of test and inspections) NOTE: Refer to pages 9 & 10 for details of plates. “Other” marking requirements • Each container should be marked with a unique identification number issued by the owner. Notes: 1. The above number should be cross-referenced on all relevant documentation. 2. The number should be prominently displayed on a minimum of 2 sides of the container in contrasting colours with stenciled characters of not less than 75 mm in height.

FORKLIFT POCKETS

ISO Containers often have more than 1 set of forklift pockets. Extreme caution should be used when lifting a laden ISO container from the forklift pockets. If there are two sets, with one set being close to the centre of the container, the inner set are designed for “Empty lifting only”. These words must be stenciled on the base frame adjacent to forklift pockets when such forklift pockets are installed. Stenciling to be 75mm in height. There are instances where ISO containers have been modified and appear to have useable forklift pockets on more than two sides, this can be a dangerous situation as forklift pockets have been found that have the fork tynes bearing on a plywood floor. Check before using and at scheduled inspection.

SLINGS

Sling sets may be chain or wire rope. • Four sling assemblies are preferred • Minimum sling angle of 60 degrees to horizontal. • Chain used in stingers (or 5th leg) must meet ISO 3076, or ISO 7593 standards. Note: The use of stingers is discouraged as the redundancy in a 4 leg assembly is lost.

SHACKLES

Shackles must be: • Grade “S” minimum Safety pin type with split pin fitted

August 1999

Page 89

APPEA

Guidelines for Lifting Equipment - Phase Out of ISO Containers

CONTAINER INSPECTIONS

ISO containers must receive a Thorough Visual Inspection both annually and prior to any load testing. • NDT Inspection of padeyes and floor support structure is to be carried out annually and prior to load testing. • All Thorough Visual Inspections and NDT must be recorded in a lifting equipment database.

THOROUGH VISUAL & NDT INSPECTIONS

• •

ANNUAL REQUIREMENT

• • • • • • • • • • • • •

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Door latching mechanisms in good working order (where applicable) Container is free from obvious defects, corrosion, impact damage, cracks, etc. Under-floor support structure inspection. The floor support structure is very light in an ISO container and is prone to extensive corrosion and cracking when used in the offshore environment. Place container on supports to allow full inspection of underside and ensure adequate lighting. Look for corrosion and/or any cracking. It may be necessary to sand blast corroded steel to allow full inspection. Suspected areas of cracking to have NDT inspections carried out. Steelwork that has suffered significant (greater than 10%) metal loss through corrosion is to be replaced. Complete structure to be examined for corrosion, cracking, and impact damage. Particular attention is to be given to inspection of lifting points and corner post assemblies. Visually inspect all welds for defects. NDT all welds in padeye area. (NATA accredited NDT contractor required) Inspect for signs of mechanical damage. Doors, frames, seals, hinges, locks should be examined and functionally checked to ensure satisfactory operation without undue force. Check floor is substantially flat with no signs of damage or other indications that may indicate overloading. Any internal floor damage may indicate underside damage- re-check. Marking Plates should be as per requirements of this document (pages 9 & 10).

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Guidelines for Lifting Equipment - Phase Out of ISO Containers

VISUAL INSPECTORS KNOWLEDGE REQUIREMENTS

The visual inspector should have, as a minimum, a knowledge and adequate practical experience of: • The statutory requirements relating to containers. • The provisions of DNV 2.7-1 (to be used as a guide only as ISO containers do not comply with offshore container standards). • The various types of containers in service. • The correct methods of slinging and handling the containers. • The loads affecting containers when handled under adverse offshore conditions, particularly those affecting lifting points and, in the case of ISO containers used offshore, the floor support structure. • The methods of testing containers as detailed in Maritime Safety. Committee circular 860 or, DNV2.7-1 Offshore Container, Certification Notes. • Defects likely to be found in containers and acceptable levels of wear, distortion and deterioration in relation to safety in use. • Welding methods and procedures and qualification of welders. • The various methods of non-destructive testing (NDT) and a good understanding of how they work and their limitations • Procedures for measuring container to ensure distortion has not occurred during service or load testing.

TESTING AN ISO CONTAINER

As all ISO containers will be phased from the Australian offshore oil & gas out by 30/12/99 it is proposed that any containers currently in use undergo the following load test (subject to satisfying inspection requirements) which would see them through to phase out date. • Testing of container as per “Testing Requirements” as detailed in IMO 613 & MSC 860. (Drop test will not be required)

TESTING PROCEDURES

Prior to load testing, carry out Thorough Visual Inspection as detailed within this document. (There is no value in testing a container that has defects) 4 Point Lifting Test: Internal Load (not to be hung under container): a uniformly distributed load, such that the combined tare of the container and test load is equal to 2.5 times the de-rated MGM. The container should be lifted with its lifting set attached to all four padeyes. 2 Point Lifting Test: Internal load (not to be hung under container): a uniformly distributed load such that the combined tare of the container and test load is equal to 1.5 times the de-rated MGM. It may be necessary to secure the weights to prevent slippage during testing The container should be lifted with slings attached to two diagonally opposite padeyes during the test. Drop Test: IMO 613 and DNV 2.7-1 require that containers be drop tested when approving type designs. APPEA does not require that ISO design containers be drop tested but the requirement will need to be met when type testing future new container designs.

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Guidelines for Lifting Equipment - Phase Out of ISO Containers

ALLOWABLE DEFLECTION DURING & SUBSEQUENT TO LOAD TESTING

COMMENTS ON DEFLECTION LIMITS

Allowable deflection limits are detailed within DNV 2.7-1 Certification notes – Offshore Containers. Refer to sections 3.7.1.2 & 3.7.1.3 of referenced DNV document.

Where deflection exceeds the maximum allowable limit, the container should be scrapped.

Offshore Container Identification Plate

OFFSHORE CONTAINER Name of Manufacturer (if known) Month/year of Manufacture (if known) Manufacturers Serial No. (if known) Maximum Gross Weight Kg at Tare Weight Kg Payload Container Kg

IDENTIFICATION PLATE MATERIAL & SIZE REQUIREMENTS

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• • • • • •

deg sling angle

Plates to be of stainless steel, 1 .5 mm thick Affixed with stainless steel rivets (not aluminium) 215 mm overall width 150 mm overall height Main heading alpha characters to be stamped 10mm in height Other alpha & numeric characters 5mm in height

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Guidelines for Lifting Equipment - Phase Out of ISO Containers

Offshore Container Inspection Data Plate INSPECTION DATA-OFFSHORE CONTAINER Container No. Maximum Gross Weight Kg Tare Weight Kg Payload - Container Kg Mid- deck (Not Applicable to ISO containers) Owner: Tel. No. +

Test

Proof Load

NDT

Visual Inspection

INTERVAL DATE & “TESTED BY”

ONCE ONLY

1 YEAR

1 YEAR

Note: The inspection frequencies shown above only apply to ISO containers INSPECTION DATA PLATE MATERIAL & SIZE REQUIREMENTS

August 1999

• • • • • •

Plate to be of stainless steel, 1 .5 mm thick Affixed with stainless steel rivets (not aluminium) 215 mm overall width 250 mm overall height Main heading alpha characters to be stamped 10mm in height Other alpha & numeric characters 5mm in height

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OK CHECK LIST.

•

REVIEW PRIOR TO ISSUING A TEST CERTIFICATE

Container was placed on supports and a full underside inspection carried out.

•

Container has no significant corrosion and/or structural fault affecting integrity Container floor is in sound condition

•

•

NDT of padeye welds and floor support structure has not revealed any cracking (or repairs have been effected)

• • •

Padeyes are fitted to the container Padeyes have engineering design drawings available Padeye design complies with the requirements of this document. Container has been de-rated as per requirements of this document Container has been load tested as per requirements of this document There is no permanent distortion of the container following load testing Forklift pocket marking is as per the requirements of this document and the pockets are in a good and safe condition. Where a 5th leg is used in a chain sling assembly, the chain in the 5th leg must meet ISO3076 standards for lifting chain. Engineering drawings and structural analysis support any modifications. All such modifications should have independent design verification.

• • • • • •

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Guidelines for Lifting Equipment

APPENDIX I

GUIDELINES FOR THE INSPECTION, TESTING AND MARKING OF OFFSHORE CONTAINERS

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

PREAMBLE The purpose of these guidelines is to address integrity requirements for existing offshore containers. The guideline does not address requirements for new container fabrication. For information on new container fabrication, refer to APPEA “Guidelines for Lifting Equipment” Neither do these guidelines address concerns with the use of ISO containers within the offshore industry. For ISO container management, refer to the APPEA Guideline for the Phase Out of ISO Shipping Containers. These guidelines will provide guidance to lifting equipment testing facilities on consistent minimum quality requirements for testing offshore containers. APPEA encourages all offshore container owners and their agents to utilise inspection services that have been accredited by NATA (or equivalent overseas organisations) to carry out inspections and/or tests in accordance with this guideline. If the required documentation needed to obtain a “Certificate of Conformity” as detailed within this guideline is not available to support the integrity of the container to be inspected and/or tested, the container should not be approved for offshore use. This may require that engineering drawings be developed and calculations carried out to verify the design of the container as being fit for intended service. Without all required information, a “Certificate of Conformity” should not be given for the container.

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

DOCUMENT SCOPE

Provide guidelines for the inspection, testing and marking of a wide range of containers, baskets, skips etc. used in the offshore oil & gas industry.

INTRODUCTION

The range of shapes, sizes and capacity of containers used in the offshore industry makes it difficult to specify all requirements that need to be met for each individual design. This document will provide specifics on some matters affecting safety of containers whilst other areas may offer guidance only. It is the joint responsibility of both the equipment owner and the inspection and/or testing facility to ensure that all containers used within the offshore industry are fit for the intended service.

REFERENCE MATERIAL

Australian Maritime Safety Authority, Marine Orders, Part 44, Section 11 International Maritime Organization Circular 613 (to be replaced by Maritime Safety Committee, Circular 860) DNV 2.7-1 Certification notes for Offshore Containers APPEA Guidelines for Lifting Equipment IMDG Code PrEN12079. Offshore Containers – Design, construction, testing, inspection and marking. Petroleum Submerged Lands Act P(SL)A ZOCA Regulations

COMMENTS ON DESIGN OF OFFSHORE CONTAINERS

APPEA has recognised that there are many containers in use within the Australian offshore oil & gas industry that may not be correctly engineered for the service. The guidelines and procedures provided in this document will assist in ensuring that every container used within the industry has engineering drawings and design calculations to support the Maximum Gross Weight indicated on the container. Without the required documentation the testing facility will have no ready method of determining if the Maximum Gross Weight (MGW) nominated by the owner, is in fact a safe working load to be applied. New containers being fabricated will be to more stringent guidelines and will be built to recognised standards such as DNV 2.7-1. This will automatically provide the quality that this document seeks to introduce to existing containers.

JUSTIFICATION OF ALLOWABLE MGW (Maximum Gross Weight) OF EXISTING CONTAINERS

Existing containers may well need to be down-rated due to the more stringent testing now required. It is recommended that container owners carry out a review of existing design MGW ratings to ensure that the container(s) will meet the testing requirements of 2.5 times MGW. It may be necessary to revise the container MGW and to update drawings as required, indicating new ratings.

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PADEYE REQUIREMENTS

One of the most critical areas in the fabrication of an offshore container is the padeyes and their attachment to the container. For this reason APPEA requires that the following be met on all offshore containers. The installation of padeyes must be carried out in accordance with good engineering practices. • No “bolted on” padeyes are permitted • Padeyes must be welded to the primary structure of the container Note: For existing containers of mono-coque construction, a detailed engineering assessment of the padeye connection is required. • Design carried out by a qualified structural engineer and checked by an independent engineer. • For design purposes, the design load is to be carried on two diagonally opposite padeyes. • Align to centre of gravity of the loaded container. • Shackle pin hole to be +3mm or, not greater than 4% more than the shackle pin diameter • Width of padeye to be equal to 75% of the opening of shackle to be fitted. This may be accomplished by fitting bosses (cheek plates) to padeye. • Material traceability where appropriate material with through thickness properties is to be specified. (Lamellar Defects) • Documented welding procedures (To AS1554, AWSD1.1 etc.) • Welder qualification trace-ability • NDT inspection of welding by MPI for all fillet welds & a combination of Ultra Sonic and MPI for full penetration welds. (NATA to assist with text) NOTES: 1. The installation of padeyes MUST have engineering trace-ability. 2. DNV 2.7-1 provides full details of container design and material requirements and designers are encouraged to use the DNV document as a guide.

GENERAL DESIGN REQUIREMENTS

• •

Mono-coque construction is not to be used in new offshore container fabrication and/or designs. i.e.: A “Primary structure” is required. For all other design requirements for new offshore containers, refer to DNV2.7-1 “Certification Notes – Offshore Containers”.

. MARKING REQUIREMENTS

All Offshore containers shall have: Marking plates for: • Operational Marking Plate (Tare, Nett & Gross) • Test Plate (date of tests and inspections) “Other” marking requirements • Each container should be marked with a unique identification number issued by the owner. Notes: 1. The above referenced “unique number” should be cross-referenced on all relevant documentation, including the “Certificate of Conformity”. 2. The number should be prominently displayed on at least 2 sides of the container in contrasting colours with stenciled characters of not less than 75 mm in height.

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

COMMENTS ON LOAD TESTING OF OFFSHORE CONTAINERS

The load test requirements for offshore containers used in Australian waters have traditionally been taken from Marine Orders Part 32 as published by the Australian Maritime Safety Authority. The APPEA lifting equipment guideline committee have recognised that this table is not suited to offshore containers and further recognise that it is the requirements of the International Maritime Organisation (IMO) that must be applied. IMO have issued a circular (613) that details testing requirements for offshore containers. This circular, referenced in Marine Orders part 44, paragraph 11 is to be replaced by circular 860. (Both circulars have similar wording.)

LOAD TESTING

Prior to load testing, carry out Thorough Visual Inspection as detailed within this document. (There is no value in testing a container that has defects) 4 Point Lifting Test: Internal Load (not to be hung under container): a uniformly distributed load, such that the combined tare of the container and test load is equal to 2.5 times the rated MGW. The container should be lifted with its lifting set attached to all four padeyes. 2 Point Lifting Test: Internal load (not to be hung under container): a uniformly distributed load such that the combined tare of the container and test load is equal to 1.5 times the rated MGW. The container should be lifted with slings attached to two diagonally opposite padeyes during the test.

DOCUMENTATION REQUIREMENTS PRIOR TO LOAD-TESTING

The following requirements apply to any offshore container including baskets, bottle racks, waste skips, completion baskets, workshops, stores and any other structure used to transport goods to and from offshore facilities. Prior to any container being load tested, the testing facility is required to make all practical effort to ensure that the container is designed for the intended loading and service. The equipment owner is required to provide the testing facility with either a classification society (e.g. DNV) approval for the container or, engineering drawings and a full design package completed by an engineer experienced in the design of offshore containers.

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

COMMENTARY ON CLASSIFICATION SOCIETY APPROVED OFFSHORE CONTAINERS

When a container with class society certification is presented to a NATA accredited facility for inspection and/or load testing, the facility is not required to verify the design. The NATA accredited facility can proceed with load testing the container and issue the Certificate of Conformity on the strength of the Class Society Certification approval and the satisfactory load test. The engineering drawings and design calculations detailed below are not required to be presented to the inspection and/or testing facility for a class society approved container. Maintaining class society certification will provide acceptance of the container at other locations throughout the world.

NATA ACCREDITED FACILTY RESPONSIBILITIES

When a container is presented to a NATA accredited facility for inspection and testing according to APPEA requirements, the facility management must recognise that they are playing a major role in ensuring the safety of offshore containers.

ALLOWABLE DEFLECTION DURING & SUBSEQUENT TO LOAD TESTING

Allowable deflection limits are detailed within DNV 2.7-1 Certification notes – Offshore Containers. Refer to sections 3.7.1.2 7 3.7.1.3 of referenced DNV document.

COMMENTS ON DEFLECTION LIMITS

Where deflection exceeds the maximum allowable limit, the container should be either, down-rated, repaired or scrapped.

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

INFORMATION TO BE INCLUDED IN ENGINEERING INFORMATION

As a minimum the engineering design drawings, calculations and specifications supplied by the container owner (when container is not class society approved) to the inspection and/or testing facility should include: • •

Name of qualified design engineer. Name of verifying engineer (Design to be verified by an independent engineer) • Specification for materials to be used in fabrication • Design Tare, Nett & Maximum Gross Weight rating • Welding specifications, consumables and weld procedures to be used All welding to be continuous fillet weld (except where otherwise specified) with size of weld to be equal to the thickness of the steel being welded or 6mm whichever is the lesser. Notes: 1. The welding methods, procedures and personnel qualifications, details, workmanship, quality and inspection should be specified to be in accordance with a recognised standard • Material traceability requirements (Critical for padeyes and plates to which padeyes attach and important for primary structure members) • NDT Inspection requirements at time of fabrication. Note: Whilst not all the following NDT work may have been carried out on an older container, the NDT on padeye welds is considered to be critical requirement 1. Wall and floor welds to have 100% visual only. 2. Padeye butt welds – 100% UT/RT (prior to load test) 3. Padeye fillet welds - 100% UT/ RT (prior to load test) 4. Padeye butt & fillet welds – 100% MPI after load test Re-weld to have 20% inspection as per original (NATA to assist) • Padeyes must be aligned to the centre of gravity of the load. • Padeyes must tie into the primary structure • Padeye hole to be 3mm or not more than 4% greater than shackle pin diameter. • Padeye width to be 75% (minimum) of opening of shackle pin diameter. This may require that bosses be welded to padeye plate. • Design of lifting set to be attached. • Details of surface preparation prior to apply surface coatings • Details of coatings to be applied to container

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

SLINGS

Sling sets may be chain or wire rope. • Six sling assemblies are not allowed • Chain used in stingers (or 5th leg) must meet ISO 3076, or ISO 7593 standards.

SHACKLES

Shackles must be: • Grade “S” minimum • Safety pin type with split pin fitted • Bow shackles are preferred

CONTAINER INSPECTIONS

Containers must receive a Thorough Visual Inspection both annually and prior to any load testing. • NDT Inspection of padeyes and floor support structure is to be carried out every 3 years and prior to load testing. • All Thorough Visual Inspections and NDT inspections must be recorded in a lifting equipment database.

THOROUGH VISUAL & NDT INSPECTION REQUIREMENTS

•

ANNUAL REQUIREMENT

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Container is free from obvious defects, significant corrosion, impact damage, cracks, etc. • Under-floor support structure inspection. • Place container on supports to allow full inspection of underside and ensure adequate lighting. • Look for extensive corrosion and/or any cracking. • It may be necessary to sand blast corroded steel to allow full inspection. • Suspected areas of cracking to have NDT inspections carried out. • Steelwork that has suffered metal loss of 10% or greater through corrosion, is to be replaced. Note: This may require UT checks to quantify metal loss. • Complete structure to be examined for corrosion, cracking, and impact damage. Particular attention is to be given to inspection of lifting points, under-side members and corner post assemblies. • Visually inspect all welds for defects. • NDT all welds in padeye area. (3 yearly)NATA to advise type of NDT • NDT a minimum of three each, selected under-floor structural welds • Inspect for signs of mechanical damage. • Doors, frames, seals, hinges, locks should be examined and functionally checked to ensure satisfactory operation without undue force. • Check floor is substantially flat with no signs of damage or other indications that may indicate overloading. Any internal floor damage may indicate underside damage- re-check. • Marking Plates should be as per requirements of this document.

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

TESTING OF WORKSHOP CONTAINERS, LOGGING UNITS ETC.

In the past, it has proven most difficult (if not impossible) to fit the required test weights into containers that have work benches, shelving etc. It is also impossible to fit weights into many logging units and other container style cabins that either are full of specialised equipment used by service companies or, only have personnel access doors. In the case of these units APPEA has considered several options & other interested parties have put forward options for ensuring on-going integrity. Hanging weights under the container does little to verify the integrity and the weights can generally only be suspended from the strongest points. This does nothing for ensuring integrity of lesser structural members. APPEA therefore proposes that more stringent inspection requirements apply to these units in lieu of any load testing.

6 YEARLY INSPECTION OF WORKSHOP CONTAINERS, LOGGING UNITS ETC.

Where test weights cannot be evenly distributed across the floor area of any container, logging unit etc. the following inspection methods shall be used to ensure the on-going integrity of the equipment. These requirements shall be additional to the ANNUAL INSPECTION requirements as detailed on page 9 Note: This method of integrity assurance will be in lieu of load testing and will only be carried out by NATA accredited NDT inspection facilities. • Place container on racks to allow full underside inspection. Note: Do NOT walk underneath containers suspended by forklift or cranes. • Abrasive blast 25% of under-floor welds. • Carry out MPI on all welds cleaned by blasting • If any cracking of welds or structural members is identified, abrasive blast a further 25% and test as described above. • Where continued cracking is found in the additional welds cleaned that have been cleaned for inspection, the underside should be completely abrasive cleaned and all welds inspected by MPI method. • Carry out UT testing of 50% of under-side structural members. Note: If any metal loss of > 10% is detected, the remaining structural members shall also be UT checked for metal loss. • Carry out repairs as required using approved welding procedures, qualified welders and trace-able materials equivalent to the original structure members as detailed on the engineering drawings. • Carry out MPI on all weld repairs and rectify any faults detected. • Re-coat underside of container with a suitable coating for the offshore environment. • NATA endorsed facility shall provide the equipment owner with a “stick diagram” of the container underside. The diagram shall identify members and joints inspected. • The equipment owner should ensure that all QA documents relating to repairs carried out are complied and retained on file for future reference.

Note: Whilst the abrasive blast requirements may, at first seem to be quite extensive, it will, in most cases be advantageous as many containers will require re-application of coatings (particularly underneath) at the end of 6 years and this work will fit well with that requirement.

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

VISUAL INSPECTOR KNOWLEDGE REQUIREMENTS

The inspector must have, as a minimum, a knowledge and adequate practical experience of: • The statutory requirements relating to containers. • The provisions of DNV 2.7-1 • The various types of containers in service. • The correct methods of slinging and handling the containers. • The loads, stresses and strains affecting containers when handled under adverse offshore conditions. • The methods of testing containers as detailed in Maritime Safety. Committee circular 860 or, DNV2.7-1 Offshore Container, Certification Notes. • Defects likely to be found in containers and acceptable levels of wear, distortion and deterioration in relation to safety in use. • Welding methods and procedures and qualification of welders. • The various methods of non-destructive examination (NDE) and a good understanding of how they work and their limitations • Techniques for measuring container to ensure distortion has not occurred during service or load testing.

Offshore Container Identification Plate OFFSHORE CONTAINER Name of Manufacturer Month/year of Manufacture Manufacturers Serial No. Maximum Gross Weight Tare Weight Payload Container Intermediate Deck Kg Certificate of Conformity No. Design Temperature

IDENTIFICATION PLATE MATERIAL & SIZE REQUIREMENTS

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• • • • • •

Kg at Kg Kg

deg sling angle

Degrees C

Plate to be of stainless steel, approximately 1 .5 mm thick Affixed with stainless steel rivets (not aluminium) 215 mm overall width 150 mm overall height Main heading alpha characters to be stamped 10mm in height Other alpha & numeric characters 5mm in height

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APPEA

Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

Offshore Container Inspection Data Plate

INSPECTION DATA-OFFSHORE CONTAINER Container No. Maximum Gross Weight (wt) Tare Weight Payload - Container Mid- deck

Kg at deg, Sling angle Kg Kg Kg (Where Applicable)

Owner: Tel. No. +

DATE:

DATE:

DATE:

TEST TYPE:

TEST TYPE:

TEST TYPE:

TESTED BY:

TESTED BY:

TESTED BY:

DATE:

DATE:

DATE:

TEST TYPE:

TEST TYPE:

TEST TYPE:

TESTED BY:

TESTED BY:

TESTED BY:

DATE:

DATE:

DATE:

TEST TYPE:

TEST TYPE:

TEST TYPE:

TESTED BY:

TESTED BY:

TESTED BY:

DATE:

DATE:

DATE:

TEST TYPE:

TEST TYPE:

TEST TYPE:

TESTED BY:

TESTED BY:

TESTED BY:

DATE:

DATE:

DATE:

TEST TYPE:

TEST TYPE:

TEST TYPE:

TESTED BY:

TESTED BY:

TESTED BY:

INSPECTION DATA PLATE MATERIAL & SIZE REQUIREMENTS

August 1999

• • • • • •

Plate to be of stainless steel, approximately 1 .5 mm thick Affixed with stainless steel rivets (not aluminium) 215 mm overall width 250 mm overall height (approx.) Main heading alpha characters to be stamped 10mm in height Other alpha & numeric characters 5mm in height

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

CERTIFICATE OF CONFORMITY

At the completion of inspection, testing and marking compliance work the NATA endorsed Certificate of Conformity (developed by APPEA in conjunction with NATA) will be issued by a NATA accredited facility In signing and approving the issue of a Certificate of Conformity the NATA accredited facility will be advising the owners, users & transporters of the container that the unit is “fit for intended service”. Where doubt exists, the NATA facility should seek clarification from a registered structural engineer, who is experienced in container design. The Certificate of Conformity will remain current for the life of the container provided no structural alterations are made. Any structural alterations will require the container to be re-assessed and a new Certificate of Conformity to be issued.

ONGOING INSPECTION & TEST REPORTS

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Ongoing, in-service reports will include the following as appropriate: • Visual Inspection Reports • Load Test Reports • Non Destructive Testing Reports

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Guidelines for Lifting Equipment - Inspection, Testing and Marking of Offshore Containers

OK REQUIREMENTS TO BE MET PRIOR TO ISSUING A “CERTIFICATE of CONFORMITY”

• • • • • • • • • • • • • • • • • • •

August 1999

Engineering drawings have been reviewed by either: A Classification Society (e.g. DNV, ABS, Lloyds etc.) An independent Qualified Engineer NATA accredited facilities qualified engineer. Drawings meet the requirements detailed within this document. Container was placed on supports and a full underside inspection carried out. Container has no significant corrosion and/or structural fault affecting integrity Container floor is in sound condition Engineering drawings and structural analysis support any modifications. Padeyes are fitted to the container Padeyes have engineering design drawings available Padeye design complies with the requirements of this document. Container has been de-rated as per requirements of this document Container has been load tested as per requirements of this document There is no permanent distortion of the container following load testing (Refer to DNV 2.7-1, section 37.1.2 & 3.7.1.3) Forklift pockets marking is as per the requirements of this document. No grade T chain is used in 5th leg of a 5 leg assembly where is there is no redundancy NDT of padeye welds, structural member welds and floor support structure has not revealed any cracking (or repairs have been effected)

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