dŴr cymru welsh water mechanical specification lifting...

DŴR CYMRU WELSH WATER

Mechanical Specification

Lifting Equipment

July 2016

.

Document ID: MS106 version 4

Dŵr Cymru Welsh Water

Mechanical Specification Lifting Equipment

MS106 version 4 of 17 July 2016 UNCONTROLLED WHEN PRINTED

Document Control

Document Number

MS106 version 4

Version Control

Version Status Date Author(s) Description of Change

1 Draft 27/02/2009 Richard Aubry First Draft for comment

1 General Issue 14/04/2009 Richard Aubry Following consultation

2 Draft 26/10/2010 Richard Aubry Periodic review

2 General Issue 29/10/2010 Richard Aubry Following Review

3 For Review 28/09/2011 Richard Aubry Following Consultation

3 General Issue 13/01/2012 Richard Aubry Following Consultation

4 General Issue 13/05/2016 Glenn Jones See page 3

Authorisation

Name Role Company Date

Andrew Bayton

Mechanical & Electrical Engineering Manager

Dŵr Cymru Welsh Water 26/05/2016

Review

This Specification is to be reviewed by 31/05/2019




Changes Made Since Last Version

Section Section Heading Changes Made

Version 4

3.6 Davits Additional paragraphs included installation and examinations details

3.8 Lifting Slings Updated to align with the statutory maintenance written scheme of examinations.




Contents

Document Control ................................................................................................................................... 2

1 Purpose ........................................................................................................................................... 5

2 Hazardous Areas Rating ................................................................................................................. 5

3 Hoists, Runway Beams and Davits ................................................................................................. 5

3.1 Procurement ............................................................................................................................ 5

3.2 Hand Operated Hoists ............................................................................................................. 6

3.3 Powered Hoists ....................................................................................................................... 6

3.4 Overhead Runway Beams ...................................................................................................... 6

3.5 Slewing Jib Cranes ................................................................................................................. 7

3.6 Davits ...................................................................................................................................... 7

3.7 Tripods, Davits and Winches for Man Riding .......................................................................... 8

3.8 Lifting Slings (Chain) ............................................................................................................... 9

4 Protective Finish ............................................................................................................................ 15

5 Testing and Certification ............................................................................................................... 15

6 Conveyance of Plant about the Site .............................................................................................. 16

7 Use of Lifting Equipment ............................................................................................................... 17

8 Data Sheets................................................................................................................................... 17

Figures & Tables

Figure 1: Lifting Sling Construction Detail ............................................................................................... 9

Table 1: Mechanical properties of the Chain assembly ........................................................................ 10

Table 2: Working load limits Grade 5 (uniform load method of rating as single leg chain assembly) .. 10

Table 3: Working load limits Grade 6 plus (uniform load method of rating as single leg chain

assembly) .............................................................................................................................................. 11

Table 4: Working load limits reductions ................................................................................................ 12

Figure 2: Dee Shackle Dimensional Identification (To be used with Table 5) ...................................... 13

Table 5: Working load limits and acceptance dimensions of chain link shackles ................................. 13

Table 6: Inspection Requirements for Lifting Equipment ...................................................................... 16




1 Purpose

This document describes Dŵr Cymru Welsh Water (DCWW) Mechanical Specification requirements for lifting equipment installations and shall be read in conjunction with the following DCWW documents:

TS001 – Introduction and Index;

MS101 - General Mechanical Specification;

The Particular Mechanical Specification for the scheme or contract.

This document covers the design, installation, and testing of:

1) Portable lifting appliances and equipment;

2) Permanently installed lifting appliances, excluding overhead cranes;

3) Lifting and transportation appliances for moving Plant from within Plant Rooms to exterior locations, and around the treatment works site.

2 Hazardous Areas Rating

The equipment rating will be decided by the particular zoning classification of the installed location,

(refer to the Zoning Plan for the scheme or contract, which will be issued with the Particular

Specification).

Electric motors located in hazardous areas shall comply with the requirements of BS EN 60079-14, IEC

60079-14 – ‘Electrical apparatus for explosive gas atmospheres. Electrical installations in hazardous

areas’.

Guidance on how to comply with the DSEAR Regulations for zone classification can be found in the

current versions of the following DCWW documents:

AM_L_PR1_005 - Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR);

The current version of the DCWW PEXA Handbook.

3 Hoists, Runway Beams and Davits

3.1 Procurement

The Lifting Equipment for procurement shall be selected from suppliers identified in relevant Framework

Agreements, providing a suitable product meeting the design criteria is available. Where the design

solution requires the procurement of a specialised product that can only be obtained from a non-

framework supplier, the design team shall specify the requirements and supplier as part of the Particular

Specification for the scheme or contract.

Where a product is available from more than one Framework Supplier, or there are no relevant

Framework Agreements, the final selection shall be made with reference to Whole Life Costs.




3.2 Hand Operated Hoists

Hand operated lifting devices shall comply with BS EN 13157 – ‘Cranes. Safety. Hand powered lifting

equipment’:

Chain blocks;

Plate side winches;

Pulley blocks for use with wire rope;

Pulley blocks for use with natural and synthetic fibre ropes;

Chain lever hoists.

Hoist units fitted to single runway beams shall be of the self-suspension type and mounted on a single

rigid trolley/traveller designed for manual/geared travel along the runway beam. End stops shall be

provided at each end of the beam compatible with the trolley provided. The trolley wheels shall have

ball or roller bearings greased packed for life.

All individual items shall be clearly marked with their respective safe working loads.

3.3 Powered Hoists

Powered hoists shall comply with BS EN 14492-2 – ‘Cranes. Power driven winches and hoists. Power

driven hoists’. Limiting devices shall be incorporated.

The electric motor driven hoist shall lift or lower the load under full control at 2 speeds; 1 m/min and 4

m/min, or the nearest equivalent commercial speeds. The hoist shall be capable of heavy "inching"

duties.

Hoist units fitted to single runway beams, fixed or jib-mounted, shall be of the self-suspension type,

mounted on a single rigid trolley designed for powered or manual geared travel along the runway beam.

End stops shall be provided at each end of the beam compatible with the trolley provided. The trolley

shall have ball or roller bearings grease packed for life.

All hoists are to be fitted with chain sacks/boxes for the loose chain.

Hooks are to be fitted with a heavy duty thrust bearing to permit 360 degree rotation of the hook under

load.


3.4 Overhead Runway Beams

Overhead runway beams and gantries shall be designed to the relevant standards:

BS 2853 – ‘Specification for the design and testing of steel overhead runway beams’;

BS 2573 – ‘Rules for the design of cranes. Specification for classification, stress calculations and design criteria for structures’.

The equipment shall be rated for a minimum of 1.5x the heaviest load to be handled. Lifting gantries

shall normally be supported by correctly designed gantry bases and not by the walls of any building

structure. However, when gantries are installed on the upper floors of a building, the designer shall

ensure that the loads imparted to the floor will be adequately and safely supported by the lower building

walls.




Effective end stops shall be provided on the runway to prevent the trolley from either falling from the

beam, or fouling the structure of the building. The stops shall not operate on the flanges of the trolley

wheels.


3.5 Slewing Jib Cranes

Slewing jib cranes shall comply with the following BS standards:

BS EN 14985 – ‘Cranes. Slewing jib cranes’;

BS 7333 – ‘Specification for slewing jib cranes’.

Surface mounted, slewing, post type cranes shall be supplied complete with stainless steel anchor

fixings. A sealant or other means shall be used to prevent the ingress of water between the anchor and

the concrete, thus preventing damage due to freezing.

The jib shall be provided with a separate attachment or trolley for the hoist and for a holding chain and

hook arrangement. This shall facilitate the lifting of pumps with lifting chains of the intermediate ring or

snatch and grab type.

3.6 Davits

Portable davit systems shall be constructed in sections that can be transported in a small van and easily

erected by one operator.

Davits shall be of the "light weight" design, which shall weigh no more than 25 kg, when they are

supplied for the lifting of plant with weights up to 500 kg.

When any section of the proposed portable davit exceeds 50 kg, then lifting equipment for its erection,

dismantling and transportation around the site shall be provided, or the davit will be permanently left in-

situ.

The jib shall be provided with a separate attachment for the hoist and one for a holding chain and hook

arrangement. This shall facilitate the lifting of pumps with lifting chains that have intermediate grab rings.

When mounted on solid RC flooring or slabs, the davit shall be provided with a permanent socket post

of 1.10 m height (short socket tubes are not permitted since they are a potential trip hazard). However,

a flush socket is permitted in circumstances where a permanent post would create an unacceptable

obstruction, as for example, where the wet well is situated under a road.

The post design shall incorporate a flat mounting plate for fixing to the floor slab via stainless steel

anchor bolts. A sealant or other suitable means shall be used to prevent ingress of water between

anchors and sockets, thus preventing damage due to freezing. A drain hole shall be provided at the

junction of the post and mounting plate to prevent the build-up of water within the post.

Flush sockets (cast-in) are normally not permitted on solid floors due to their tendency to accumulate

water and debris which impairs use. However, flush sockets are acceptable when fixed to a fabricated

steel flooring, provided that the tube is open at the bottom and can free-drain. In circumstances where

a flush, cast-in socket is the only practicable solution, it must be equipped with a captive/tethered cover

designed to limit the ingress of debris.

Davit sockets should be designed and positioned to provide lifting equipment with a vertical pull on the

pump unit lifting attachments, to enable pump units to be readily raised or lowered on their guide rail.




Davit sockets shall be installed strictly in accordance with manufactures’ recommendations using the

correct fixings and allowing the correct clearance distances to edges of structures and should be rated

to lift twice the weight of each pump unit, subject to a minimum Safe Working Load (SWL) of 500 kg.

Before first use, arrangements shall be made for a “Thorough Examination” of the davit sockets. The

“Thorough Examination” should include examination of the supporting structure or ground works, the

construction of the davit and also the methods of fixing. When the installer is satisfied that the installation

is satisfactory the davit should be load tested in situ. Each socket shall be provided with a certificate of

conformity by the manufacturer.

The “Thorough Examination” may be carried out by the installer; however, the installer may need to

refer to a suitably qualified engineer (civil, structural, etc.) to approve the installation. A copy of the

Certificate of Approved Installation should form part of the overall documentation package and should

be made available to the DCWW appointed Competent Person (as defined in the Lifting Operations and

Lifting Equipment Regulations (1998). Each socket shall be proof load tested on installation and a

certificate of conformity issued by the installer.

Material selection should consider reducing the likelihood of corrosion and any detrimental effect from

surrounding environmental conditions (for example: corrosive attack from wet well atmospheres, saline

attack from coastal environments). In addition, davit sockets should be free-draining and be equipped

with cover plates if ingress of water and debris is to be prohibited. Cover plates shall be captive/tethered

to the davit socket and must be flush with the surrounding floor level to avoid creating a trip-hazard.

3.7 Tripods, Davits and Winches for Man Riding

Davit and tripod systems for man-lifting or rescue operations shall be designed in accordance with BS

EN 1496 – ‘Personal fall protection equipment - Rescue lifting devices’.

All equipment shall be designed with a safety factor of not less than 8 for mechanisms, and 10 for wire

ropes.

Davit and tripod systems shall be portable and made in sections that can be easily transported in a

small van and erected by one man. They shall be designed for a safe working load of not less than 254

kg, and be provided with a separate attachment point for the hoist, and one for a rope with fall arrester,

for use as secondary means of lifting.

Davit and tripod systems shall be supplied with a fail-safe, self-sustaining wire rope hoist with governor

controlled lowering system with a speed of 0.5 m/s, and safety hook suitable for man-riding. The hoist

shall be of the extended boom type with integral pulley for wire rope and safety hook attachment to the

davit. The wire rope shall be able to reach the lowest position that the equipment is designed for and

shall not be less than 25 m unless otherwise specified.

When mounted on solid RC flooring or slabs, davits shall be provided with a permanent socket post of

1.10 m height (short socket tubes are not permitted since they are a potential trip hazard). However, a

flush socket is permitted in circumstances where a permanent post would create an unacceptable

obstruction, as for example, where the access point is situated under a road.

The post design shall incorporate a flat mounting plate for fixing to the floor slab via stainless steel

anchor bolts. A sealant or other suitable means shall be used to prevent ingress of water between

anchors and sockets, thus preventing damage due to freezing. A drain hole shall be provided at the

junction of the post and mounting plate to prevent the build-up of water within the post.

Flush sockets (cast-in) are normally not permitted on solid floors due to their tendency to accumulate

water and debris which impairs use. However, flush sockets are acceptable when fixed to a fabricated




steel flooring, provided that the tube is open at the bottom and can free-drain. In circumstances where

a flush, cast-in socket is the only practicable solution, it must be equipped with a captive cover designed

to limit the ingress of debris.

Where a man riding winch and tripod is provided to be used in the operation and maintenance of the

Plant where access is required through a manhole or similar entry point, then hardstanding shall be

provided around the manhole that it is intended to be used over. The dimensions of the hardstanding

shall allow all the feet of the tripod to be sited on it when the legs of the tripod are fully extended, and

include an additional margin of not less than 300 mm from any one foot to the edge of the hardstanding.

The surface of the hardstanding shall be flat and without irregularities in its surface, which would not

allow the feet of the tripod to rest flat.

3.8 Lifting Slings (Chain)

3.8.1 General

Chain lifting slings shall be supplied in accordance with the following specifications, and are typically

used for lifting submersible pumps and mixers from wet wells or tanks.

3.8.2 Materials of Construction

The chain sling shall be manufactured with an oval master link at each end and at approximately every

metre interval. (Allowing for the variations in chain pitch and number of links needed to achieve a

Segment Length (SL), see Figure 1 below), and supplied with a bright polished surface finish to all

components used in the assembly.

Figure 1: Lifting Sling Construction Detail

The nominal standard bearing to bearing length (reach) is calculated as number of segment lengths

required + 1 master link (inside length). See Table 2 & Table 3 below.

The completed chain sling assembly should be of suitable length to enable the removal of the

submerged plant by standard lifting equipment.

The size range will be to suit Working Load Limit (WLL) capacities of the nominal chain diameters as

outlined in Table 2 and Table 3 for grade 5 & 6 Plus respectively.

To be used in the uniform load method of rating as a single leg, with a minimum factor of safety of 4:1.

The sling (lifting chain) will comply in all respects with the requirements of the Supply of Machinery

(Safety) Regulations 2006/42/EC Regulations 2009 (Specifically to the section of the original directive

4.1.2.5 section (b) which states that only welded short link chain must be used for lifting). Short link

chain being defined as the internal length (pitch) of the chain is 3 x the nominal chain diameter, subject

to the standard manufacturing tolerances when new.




3.8.3 Material Specification and Standards of Manufacture

Chain and components: 1.4404 (AISI 316L) for chain, and1.4571 (AISI 316Ti) + 1.4462 (AISI 308 LN

in which the proportion of carbon is limited) for forged components. (Table 1 shows the mechanical

properties for both grade5 and 6+ for which the chain and components shall meet or exceed)

No specific EN or BS standard is available for stainless steel lifting chains;

Chain: Grade 5 and Grade 6 Plus (with enhanced loadings) are based on DIN 5687-1 and EN 818 -2

non- calibrated medium tolerance chain (short link) for lifting purposes, and the manufacturer’s (i.e.

Pewag) works standard and technical files for each product.

Components based on EN 1677 forged steel components for lifting slings and the manufacturer’s (i.e.

Pewag) works standard and technical files for each product.

Machinery directive 2006/42/EC (effective from December 29th 2009)

Table 1: Mechanical properties of the Chain assembly

Mechanical properties Grade 5 Grade 6 Plus

Breaking Stress 500N/mm² minimum 630N/mm² minimum

Breaking Elongation 20% minimum 20% minimum

Stress at MTF (Manufacturers Test Force) 250 N/mm² 315 N/mm²

Stress at WLL (Working Load Limit) 125 N/mm² 160 N/mm²

Table 2: Working load limits Grade 5 (uniform load method of rating as single leg

chain assembly)

Chain

Grade

Chain (nominal) Diameter (Ø mm)

WLL (kg)

Master

link

Master link (Internal) nominal

dimensions (mm)

Joining link

Joining link (internal) nominal

dimensions) (mm)

No of chain

links per segment

Segment Length

SL (mm)

Length of

master link

(mm)

Weight per

segment (kg)

5 5 500 AWI

10

10Øx80x50 BWI 7 7Øx36x16 53 1000 80 0.68

5 7 1000 AWI

13

13Øx110x60 BWI 9 9Øx44x20 37 975 110 1.33

5 10 2000 AWI18 18Øx135x75 BWI 13 13Øx54x25 25 993 135 2.91

5 13 3200 AWI

22

23Øx160x90 BWI 16 17Øx70x34 17 963 160 4.84

5 16 5000 AWI

26

27Øx180x100 BWI 20 20Øx85x40 13 974 180 7.38

5 20* 8000 AWI

26

27Øx180x100 BWI 22 23Øx115x50 21 2030 180 21

Grade

4+

26* 12000 AWI

45

45Øx340x180 BWI 32 32Øx150x70 19 2122 340 43.20

*Supplied as a standard base length of 2 x SL




Table 3: Working load limits Grade 6 plus (uniform load method of rating as single leg

chain assembly)

Chain

Grade

Chain (nominal) Diameter (Ø mm)

WLL (kg)

Master link

Master link (internal) nominal

dimensions (mm)

Joining link

Joining link (internal) nominal

dimensions (mm)

No of chain

links per segment

Segment length

SL (mm)

Length of

master link

Weight per

segment (kg)

6+ 4 200 AWI 6 6Øx60x36 - - 77 984 60 0.39

6+ 4 400 AWI 8 8Øx60x35 BWI 5 5Øx26x13 73 988 60 0.43

6+ 5 560 AWI 8 8Øx60x35 BWI 7 7Øx36x16 53 943 60 0.62

6+ 5 630 AWI10 10Øx80x50 BWI 7 7Øx36x16 53 963 80 0.68

6+ 6 850 AWI10 10Øx80x50 BWI 7 7Øx36x16 47 998 80 0.90

6+ 7 1250 AWI

13

13Øx110x60 BWI 9 9Øx44x20 37 975 110 1.35

6+ 8 1600 AWI

13

13Øx110x60 BWI10 10Øx44x20 33 990 110 1.70

6+ 10 2500 AWI

16

16Øx110x60 BWI13 13Øx54x25 25 968 110 2.60

6+ 13 3500 AWI

18

18Øx135x90 BWI

16

17Øx70x34 19 1016 135 4.50

6+ 16 6300 AWI22 23Øx160x90 BWI20 20Øx85x40 15 1050 160 8.00

3.8.4 Safe Working Load

The Safe Working load (SWL) requirements are to be determined by the specifiers/designer after

consideration of all aspects of the application. The SWL can be the same as the WLL but cannot exceed

the WLL of the sling assembly.

The SWL shall include a minimum allowance of 50% of the dry weight of the equipment to allow for hazardous service conditions e.g. fretting, breaking out from suction, friction, blockages within the equipment casing and possible additional shock loads exerted by electrically operated winches or hoists. The designer shall also take the weight of the chain sling into consideration when specifying the SWL. Other considerations are detailed below in Table 4 below.




Table 4: Working load limits reductions

Chain Temp -40°C +350°C Over 350°C

Load factor 1 Not permissible

Edge loading R = radius of corner more

than 2 x d chain diameter

R = radius of corner more


R = radius of corner smaller


Load factor 1 0.7 0.5

Shock load Slight Medium Strong Impact

Load factor 1 0.7 Not permissible

3.8.5 Marking of Components and Chain

All components and chain used in the construction of the lifting chain assembly shall be marked with

manufacturers name or mark, country of origin, grade or type of material, batch or traceability code as

required by the Machinery Directive 2006/42/EC.

3.8.6 Shackles

A safety pin chain link Dee shackles (type CLS) (“A type” screw pin with longer length complete with

split pin) (Table 5 shows typical dimensions) shall be supplied and attached to one end of the chain

assembly.

The shackle shall be manufactured from ISO 1.4401/4 (marine grade stainless steel 316L). The shackle

is to be made captive to the chain sling assembly using a non - welded rivet pin.

The designer shall ensure that the size of the shackle is sufficient to enable its attachment to the lifting

handle on the pump, and that it is of a working load limit (WLL) at least equal to that of the chain

assembly that is to be attached.

Each shackle will have the following information stamped or etched onto the shackle body

Identification of material or grade i.e.316 Stainless.

Nominal size

Working load limit (WLL) in tonnes.

Manufacturers traceability batch code

Individual serial number

CE marking




Figure 2: Dee Shackle Dimensional Identification (To be used with Table 5)

Table 5: Working load limits and acceptance dimensions of chain link shackles

Code WLL tonne

Body mm d1

Pin mm d2

Pitch mm L

Jaw mm w

a mm

b mm

c mm

Weight kg

CLS 1.25t 1.250 9.5 12.5 42 20 25 2 15 0.15

CLS 2.5t 2.500 15.8 19 65 32 40 3 22 0.55

CLS 3.5t 3.600 19 22 77 38 45 4 28 1.00

CLS 5t 5.000 22 25 88 44 55 4 29 1.90

CLS 6.3t 6.300 25 28 103 51 65 4 34 2.3

CLS 9t 9.000 31.75 34.93 128 64 85 5 38 4.35

CLS 12t 12.000 34.93 38.1 140 70 85 5 50 5.30

3.8.7 Marking of Completed Slings

The completed sling assembly will show the following particulars:

Identification of the manufacturer (Name or Symbol or recognised mark);

Identification of material or grade i.e. grade 6 Plus, Stainless steel;

Nominal chain size and number of legs;

Working load limit (WLL) in kilograms or tonnes;

Serial number of the sling;

Year of manufacture;

DCWW unique asset identification number (or space made available on the tag for local stamping).




In general this will be marked on to a tag of an accepted format normally in the shape of a five pointed star (grade 5) or in the case of grade 6 Plus a new style six pointed star tag manufactured from a compatible material (stainless steel) fixed permanently to the lifting sling.

Following final proof load testing and thorough inspection by a competent person, a CE mark should

be affixed to sling by stamping of the tag.

*Important note: Cold stamping of any product information, serial numbers, and batch codes directly

to the master links must be avoided to eliminate potential stress cracking of the component. This is

particularly important when the master links are of the formed and welded type. It should also be

stressed that round master links of a welded and circular format cannot be used in the construction of

the pump chain assembly due to high risk of excessive stresses to the weld.

3.8.8 Certification and Documentation

The chain sling assembly and shackle will each be issued with an EC declaration of

conformity/manufacturers certificate, accompanied with a user manual, and it is these original

manufacturer’s documents that must accompany the equipment before entering service for the first

time, without which the chain assembly and shackle cannot be used.

3.8.9 Risks Associated with Chain Slings / Limitations of Use

DCWW have in operation a written scheme for examination and inspection of pump lifting slings. The

scheme is reviewed regularly and subject to updates as and when necessary. Up to date information

on the Written Scheme of Examination and the inspection frequency for chain slings and all types of

lifting equipment can be obtained from the Statutory Maintenance Department.

[email protected]

The scheme allows stainless steel 316 to be suitable for use in liquids/substances in the pH range value

of 4.9 to 10.1.

Typically sewage pH values are in the range 5 to 7, and clean water pH values are in the range 4.9 to

10.1. Any chains operating in water outside this range are excluded from this written scheme.

A list of locations where the chains do not meet the requirements for pH values listed is available, (It

does not mean however that stainless steel chain assemblies cannot be used, only that they are outside

of the written inspection scheme, and the designer should consult with DCWW to confirm the pH values

in the area where new chains are to operate, so that a frequency of examination can be determined.

3.8.10 Top Bracket

A suitable bracket shall be provided at the top of the well or chamber to allow a safe method of securing

chains while in service, keeping all slack chain away from the risk of entanglement with the submerged

plant. The designer shall consider work at height and risk of falls into wells and chambers while attaching

lifting equipment to the chain. The need for the operator to lean over edge protection or enter confined

spaces to attach slings to lifting equipment shall be eliminated where reasonably practicable.

3.8.11 Spare Slings up to 10,000 Kg SWL

Submersible chains are examined in batches after removal from service. To enable this 5 year rotation,

20 % additional service chains shall be provided, i.e. where one to five similar chains are provided for

the contract then a suitable spare chain shall be provided; if six chains are supplied then two suitable

spares shall be provided etc. Every chain in the batch shall be capable of fulfilling the duty of the others.

mailto:[email protected]




3.8.12 Spare Chains over 10,000 Kg SWL

These chains are outside the scope of the written scheme of examination and are subject to 6-monthly

thorough examinations. Therefore all submersible chains over 10 tonne SWL shall be provided with an

identical spare to enable changeover for examination.

3.8.13 Multi Leg Chains

Where the equipment requires more than one point of attachment a suitable multi-leg chain sling shall

be provided as an accessory. The rules for spare chains apply equally to multi-leg chain slings.

3.8.14 Point of Attachment

Where reasonably practicable the equipment’s point of attachment shall have the same resistance to

corrosion as the stainless steel chains.

4 Protective Finish

All gantries, portable/fixed lifting systems and associated equipment shall be protected against

corrosion as defined in the DCWW Mechanical Specification – MS101 General Mechanical

Requirements. When painted, the finished colour shall be a full gloss yellow colour no. 356 to BS 381C

or equivalent reference 08 E51 to BS 4800.

5 Testing and Certification

All lifting Appliances shall be tested and supplied with an Individual Test Certificate (Certificate of

Conformity), for each item of lifting equipment which shall include:

The name of Dŵr Cymru Welsh Water for the “Owner or Occupier”;

The serial number;

The Safe Working Load (SWL);

Dŵr Cymru Welsh Water’s Asset Number.

Testing and certification shall normally be carried out as soon as possible after installation at site, and

commissioning checks have been completed.

Where lifting equipment is provided with the purpose of forming an assembly, then one test certificate

shall be provided for the complete assembly. The test certificate shall clearly and unambiguously

identify the components comprising the complete assembly, together with the instruction that this

assembly shall not be separated. (e.g. where a powered hoist is permanently fixed to a trolley, then this

shall be considered as an "assembly" for the purpose of testing and certification.)

Davit systems with cast in, floor bolted, or other type of davit socket shall also be proof load tested to

125 % SWL on site. Each socket shall be marked with the SWL and provided with a separate certificate.

Lifting equipment provided for man riding shall be specifically tested and certified for this purpose. All

such equipment shall be designed with a safety factor of not less than 8 for mechanism and 10 for wire

ropes, and shall be marked and supplied with test certificates.




Chain slings shall be procured through an appropriate supplier/test house, which is certified to ISO 9000

quality standard. The results of proof load test shall be certified on the certificate of test and thorough

examination. Prior to being put into service the original certificate shall be provided to the operators

statutory co-ordinator who add the item to the Zurich database and tag the item for its next thorough

examination. Copies of the certificates are to be included in operating manuals and or, H&S files in line

with agreed AMA practice.

In addition to the requirements of the LOLER - Lifting Equipment and Lifting Operations Regulations

(1998), all submersible equipment, such as chain slings for lifting submersible pumps and mixers, shall

be proof load tested to twice the Safe Working Load.

All lifting equipment shall be subject to periodic inspections as stipulated in Table 6 below. (Note that

these inspection intervals are maximums.)

Table 6: Inspection Requirements for Lifting Equipment

Type of Equipment Inspection Requirements

Lifting Equipment for lifting Plant/Machinery Every 12 months

Lifting Accessories e.g. chain or wire slings Every 6 months

Man Lifting Equipment Every 6 months

Lifting slings that are specified within section 3.8 and therefore covered within the scope of the Written Scheme

Every 60 months.

All examinations of lifting equipment are to be undertaken by a designated competent person. The

competent person may rule that a particular item of lifting equipment for plant (or an accessory thereof)

may be examined at longer intervals, based on the present condition, the environment and frequency

of use, provided that the examinations are scheduled.

6 Conveyance of Plant about the Site

When an item of plant/equipment is required to be removed, from an internal location or to the exterior

of a building, this shall be achieved without the need for multiple “lifts”. Overhead runway beams and

travelling cranes shall be designed to move the item to a loading bay, at the extremity of the building,

where it can be loaded onto a vehicle or allow the vehicle to pick up the item itself, at the loading bay.

Installation of permanently fixed lifting equipment shall include satisfactory and safe access for

maintenance and periodic inspection.

Where treatment plant is required to be removed by mobile lifting equipment, then satisfactory space

and hardstanding shall be provided for the access, movement and operation of the mobile lifting

equipment.




7 Use of Lifting Equipment

If existing lifting equipment owned by DCWW (other than slings, shackles or similar items) is required

to be used for installation purposes, it shall be subject to an approved method statement for the intended

use. In such cases the Safe Working Load of the existing lifting equipment shall not be exceeded.

All existing lifting appliances installed at a new location shall be retested and provided with a Certificate

of Conformity.

All lifting equipment to be provided under the contract (other than slings, shackles or similar items), may

be used for installation purposes provided it has been tested and certified before use, and that it is

restored to its original condition upon completion of its use and re-tested complete with the issue of

further Certificates of Conformity.

8 Data Sheets

The duty requirements and other data for lifting equipment shall be specified using the following DCWW

standard Data Sheets:

DS106A – Lifting Equipment – Davits;

DS106B – Lifting Equipment – Monorail Hoists.

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