Code of Practice for Selection, Management, Use, Maintenance and Examination of

Hand Chain Blocks & Lever Hoists in the Offshore Environment

including Sub-sea

Published by the:

Lifting Equipment Engineers Association

3, Osprey Court, Kingfisher Way, Hinchingbrooke Business Park, Huntingdon PE29 6FN

United Kingdom Tel:+ 44 (0) 1480 432801 Fax: + 44 (0) 1480 436314

E-mail: mail@leea.co .uk Website: www.leea.co.uk

Ownership

Name: ____________________________________________________ _

Company: ________________________________________________ __

Department: -----------------------------------------------

Disclaimer

This code of practice will be found to be a usefu l and authmitative source of infonnation for all those people who are respons ible for safety in the selection, management, use, maintenance and examin ation of hand chain blocks and lever hoists in the offshore environment including sub-sea.

Every effort has been made to achieve the highest degree of accuracy in the generation of the data and advice supplied, but ultimate responsibility for safety must continue to rest with the persons and organisations charged with specific duties in current legislation.

Second ed ition . ............ April2010

All rights reserved. No pa11 of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means, without the prior written permission of the Lifting Equipment Engineers Association.

Lifting Equipment Engineers Assoc iation 2010

CONTENTS

Foreword ... .... ....... ...... .. . ... ..... ... ... .............. 1 Statement by HSE OSD ........... ....... ..... ..... . . ............... ...... ..... 2 Organisations cooperating with LEEA in drafting thi s code ... .......... ....... ....... 2

Section I Legal requirements 1.1 Introduction ...... .................. ............ ... ........ ... ........... ...... 3 1.2 Current legis lation .. .... .. .. .. ....... .. ... ...... ..... .... .. .. ..... . ..... 3 1.3 Summary oflegal requirements .. . ..... ............... ........... ... .4

Section 2 Selection of equipment 2.1 General .............. .... ......... . .... .4 2.2 Types of hand chain blocks... . .. ..... ........ 6 2.3 Types of! ever hoists ...... .......... ...... . ................. ........ .. 8 2.4 Alternatives to hand chain blocks and lever hoists ....... ..... ... 9 2.5 Hazardous conditions.......................................... . .. ... 9

Section 3 Information to be provided 3. 1 Legal commentary ................... .... ........ ...... . . .... 10 3.2 Hand chain blocks- Information which should be

provided by the equipment specifier .......... ........... 10 3.3 Lever hoists- Information wh ich should be

provided by the equipment specifier ... . 11 3.4 Hand chain blocks and Lever hoists - Information

to be provided by the supplier .... .... ..... . . ..... .. 11

Sect ion 4 Thorough examination including verification testing 4. 1 Legal commentary......... .. .. .......... ....... .......... .... .... . ... 12 4.2 New equipment prior to supply .. . 12 4.3 In-service equipment .. .... ......... . 13 4.4 Records and reports . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . .. ... ..... ...... 15

Section 5 Requirements for transportation, storage and control 5 .I Preparation of equipment prior to despatch .. .... .................. 16 5.2 Transportation and storage conditions ................................. 17 5.3 Management of issue and return to store .......... ....... ........... 17 5.4 Cleaning of equipment. . . ........... .... ............... .. ... .... ...... 20 5.5 Inspection prior to and following use... .... ....... ... . ....... .... 20 5.6 Quarantine of unserviceable equipment......... . ..... 23

Section 6 Maintenance 6.1 Legal commentary......................... . ........ ......... .. 23 6.2 Maintenance whilst in store offshore. .. .. .. 24 6.3 Periodic maintenance...... .... ...... .. ........ ...24 6.4 Suitable lubricants ........... .. ........................ ... ........ .. ... ... ..... 26

Section 7 Historical records 7.1 Records to be kept for the life of the equipment..... .. .. 27 7.2 Records to be kept for a limited period ..................... .. ........ 27

Section 8 Planning the lifting operation and safe use of hand chain blocks and lever hoists ............................................................... 28

Section 9 Training and competency 9.1 Legal commentary .................. .. ........................ 30 9.2 Essential knowledge for the planner and operatives ............ 31

Appendix A Check list for thorough examination of hand chain blocks ..... 33 Appendix B Check list for thorough examination of lever hoists ................ 36 Appendix C Model data sheet to identify equipment required

and conditions of use...... .. ........ .. ....................... 39 Appendix D Model report of thorough examination ..... . . ........ ...... ..... .41

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CODE OF PRACTICE

Foreword This code of practice has been developed by a working group of the LEEA Technical Committee wh ich included representatives from the industries which supply, maintain and thoroughly examine hand chain blocks and lever hoists as wel l as representatives of the users and the Health & Safety Executive Offshore Division.

It is app licable to both new equipment and equipment which has previously been in serv ice.

Its purpose is to address the specific problems associated with using such equipment in the offshore and sub-sea environments and does not therefore necessari ly deal with the more general aspects of using such equipment. For guidance on the more genera l aspects see the LEEA Code of Practice for the Safe Use of Lifting Equipment.

The code is based on current knowledge and accepted good practice. However in parallel with developing the code, the HSE have commissioned a test programme to collect data about the perfonnance of typical hand chain blocks and lever hoists under the marine/sa liferous conditions experienced offshore and sub-sea. The guidance in this code wil l be reviewed once the resu lts of those tests are avai !ab le.

The conditions in the offshore environment (ie marine/saliferous) are often such as to accelerate the deterioration of equipment compared to normal industrial usage. Offshore duties can include extremes of temperature, exposure to corrosive conditions and frequent use up to the maximum capacity. Selecting equipment most suited to this enviroru11ent can mitigate some of the consequences but good maintenance, examination, inspection, transp01tation , storage and control are equally essential and the code addresses all these matters .

It is recognised that some band chain blocks and lever hoists may be pem1anently kept and used only within offshore workshops where the conditions are comparable with normal industrial usage. If controls are in place to prevent the transfer of such equipment to areas where the marine/saliferous conditions outlined above prevail, then the code may not be relevant to such equipment. However if there is the possibi li ty of equipment transfer, it is

recommended that the code should apply to the who le installation or platform or vessel.

Although specifically developed for use by the offshore industry, thi s code may be found of value in other industries which use equipment in arduous environments.

Statement by HSE/OSD The Offshore Division of the UK Health & Safety Executive strongly support the issue of this Code of Practice which the Executive see as an important step in helping to contribute towards the reduction of the number of incidents involving hand chain blocks and lever hoists which are being operated and maintained in the offshore environment.

Organisations cooperating with the LEEA in drafting this code of practice Health & Safety Executive OSD ICE IMCA Shell UK

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Section I Legal requirements 1.1 Introduction Since its introduction in 1974, the Health and Safety at Work etc Act has become the prime legislation covering the safety of equipment for use at work including lifting equipment. It makes broad requirements and acts as an ' umbrella ' for all the other regulations. Referring to employment and equipment in general rather than specific categories, the Act has the effect of uni fy ing the basic safety requirements . The Health and Safety at Work Act app lies to the offshore industry as a result of the Application Outside Great Britain Order 1995: SINo 263.

During the 1990s, the need to implement European Directives made it necessary to withdraw much of the old sectoral legis lation and introduce new UK regulations.

The earlier legislation applicable offshore (SI I 0 19) used the term 'duty holder' but the current legislation referred to below uses the term 'employer'.

1.2 Current Legislation There are three main regulatory documents currently applicable in the UK sector covering lifting equipment and lifting operations. They are: (1) The Health and Safety at Work Act 1974 as extended to apply to the

offshore industry as a result of the Application Outside Great Britain Order 1995: Sl No 263 .

(2) The Provision and Use of Work Equipment Regulations 1998: SI 2306 (PUWER) which cover the non-lifting aspects of operations involving lifting equipment.

(3) The Lifting Operations and Lifting Equipment Regulations 1998: SI 2307 (LOLER) which specifically cover lifting equipment and lifting operations.

The supply of new lifting equipment is covered by The Supply of Machinery (Safety) Regulations 2008. These implement the European Machinery Directive (2006/42/EC).

Both PUWER and LOLER are supplemented by Approved Codes of Practice (ACoPs) and guidance notes . The ACoPs give practical advice on how to comply with the law. If you follow the advice then you will be doing enough to

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comply with the law in respect of those matters on which tbe ACoP gives advice.

You may use alternative methods to those set out in the ACoP in order to comply with the law. However, the A CoP has a special lega l status. If you are prosecuted for a breach of health and safety law and it is proved that yo u did not follow the re levant provisions of the ACoP, you will need to show that you complied with the law in some other way or a com1 will find you at fau lt.

1.3 Summary of Legal Requirements In terms of effect, the requirements of the current Regu lations do not alter greatly what has been required since the Health and Safety at Work etc Act was introduced in 1974. However they do deal with the subject in greater detail. In the context of lifting operations and lifting equipment, they require: (I) The equipment must be safe and suitable for its intended purpose. (2) Manufacturers and suppliers must provide information on the safe use of

their equipment. (3) Those obtaining equipment for others to use must ensure it is safe and

suitable for the intended purpose. (4) The lifting operation must be adequately planned, supervised and canied

out in a safe matmer. (5) The personnel who use the equipment must be suitably trained. (6) The equipment must be maintained in a safe condition. (7) That declarations of confonnity and records of thorough examination etc

must be kept.

Section 2 Selection of equipment 2.1 General This code deals with hand chain blocks and lever hoists but the user should also consider whether there are more suitable alternatives. Hand chain blocks are designed for use in the vet1ical plane only and, whi lst most makes wi ll tolerate some dev iation from the vet1ical, there is other equipment more suitable for inclined loading or pull ing loads in the horizontal direction eg lever hoists which are designed to operate in any plane.

Both these items should only be used in applications where they are free to articulate with their attachment points and align so that the load line is a straight pu ll.

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Both items conta in components which will corrode in a marine environment and, as a result, may seize or their functionality may be greatly impaired. They also contain components which may cease to function correctly as a result of lack oflubrication or contamination with lubricants. When se lect ing chain blocks and lever hoists for offshore applications the user should be aware of the harsh environmental conditions which exist offshore and especially the effects that such conditions can have on the component parts which make up the blocks and hoists. Situations where the block or hoist will remain in-situ for long periods of time without being used can lead to problems with accelerated conosion of components, difficulties in pre-start inspections, maintenance etc. Al l hand chain blocks and lever hoists have a brake mechanism which relies on sufficient torque, arising from the load lifted, to operate satisfactorily. There is therefore a MINJMUM load they can safe ly sustain as well as a maximum. The minimum specified in sections 2.2 and 2.3 and verified in sections 4.2 and 4.3 is 5% of SWL. However exposure to a marine environment can increase the minimum load required to operate satisfactori ly. We therefore recommend ti1at THE M[N!MUM LOAD LIFTED SHOULD NEVER BE LESS THAN 10% OF THE SWL. ln add ition to the above, consideration should also be given to the fo llowing: (I) If the block or hoist was first provided for use in the undertaking between

3 1" December 1992 and 28'h December 2009, the employer must ensure that it has been designed and constructed in compliance with the essential hea lth and safety requirements of the Machinery Directive (98/37/EC). If however, the block or hoi st was first provided for use in the unde11aking after 28'" December 2009, the employer must ensure it has been designed and constructed in compliance with the essential health requirements of the Mach inery Directive (2006/42/EC). This is a requirement of PUWER (SI 2306) Regulation I 0. One method of achieving this is to obtain the EC Declaration of Conformity for the item alternatively ensure that the CE marking bas been affixed to the equipment.

(2) The block or hoist must have a current report of a thorough examination containing the infonnation required by Schedule I of LOLER (SI 2307) and stating that it is safe to operate.

(3) Length of load chain and hand chain required. (4) Ava ilable headroom. (5) Degree of portability reqnired. (6) Operating effort available (particularly for larger capacity blocks)

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Notes: (!) Attention is drawn to the ACoP (paragraph 177) to Regulation 6(1) of

LOLER. This states that: "Hooks and other simi lar devices provided for li fting should be of a type that reduces the risk of the load becoming displaced from the hook or other devices."

This requirement can be met by, for example, the use of hooks with safety catches or by the use of 'C' hooks.

(2) The term 'safe working load' or 'SWL' has been used thwughout this code as it is the term used by LOLER. Although, strictly speaking, this may be different from the working load limit or WLL, for the purposes of this code it has been assumed that the blocks and hoists will always be rated with their SWL equal to their WLL, ie nonnally rated. In the event that a particular app lication requires a block or hoist of higher duty, it is recommended that the lifting operation plan specifies a block or hoist which is normally rated but of appropriately higher capacity. For a full explanation of these terms, see paragraph 1.2.26 of the LEEA Code of Practice for the Safe Use of Lifting Equipment.

2.2 Types of hand chain block Because of the number of different makes of blocks currently avai lable the following information is of a general nature only and may vary from one manufacturer to another. Some manufacturers can also supply blocks which are designed and constmcted to be more resistant to the adverse effects of the offshore environment than the standard product intended for general industrial use. Whenever possible users should specify these types of unit from their supplier in preference to the standard product. Alternative types of equipment should only be considered by comparison with such specifica lly manufactured items.

Method of Attachment The block may be of 'suspended ' or ' built in' pattern, many manufacturers producing both options. Suspended types nonnally have a top hook by which the block is hung and which allows a degree of articu lation between the block and the supporting structure. Built in types are usually combined with a purpose made travelling trolley, although a direct connection to the supporting structure may also be possible. The connection between the block and the trolley or structure is usually rigid . Some designs of trolley incorporate a braking device which is effective for track inclines of approximately 6 maximum. Other options include rack and pinion drive if movement under load

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on an inclined track is required. These options should be considered if tilt is ltkely eg on a vesse l likely to roll.

Number of Fa lls of Chain The lower capacity blocks ( eg 500kg, It) lift the load on a single fall of load chain . Higher capacity blocks may either be of simi lar design but with a larger frame or may utilise two or more fa lls of load chain. The very high capacity blocks may utilise a combination of a larger frame and multiple falls of load chain and may even have two or more frames linked by a yoke. The various configurations avai lable each have their own advantages and disadvantages with regard to weight size, minimum drawn up dimension, hand chain effort required and cost.

Grade of Components Some load bearing components such as chains and hooks are graded according to their performance and may vary between makes and models of blocks. The higher the grade, the smaller and lighter the component wi ll be for a given safe working load. Modem blocks use a lloy chain of either grade T(8) or V( 1 0). Such alloy chains are susceptible to Hydrogen embrittlement if exposed to acidic conditions.

Slack Chain Collection The majority of hand chain blocks are purchased without provision for storing the slack chain, so that when the load hook is in a raised position, the slack chain hangs free ly from the block forming a loop. In some applications this can present a hazard, with the risk of the slack chain becoming caught on obstructions or itself becoming a hazard to persons. A condition can also occur where the brake is held open by the weight of the slack chain. Some manufacturers and suppliers are able to offer a collecting box to house the slack chain thereby minimising the risks.

Where a block is to be fitted with a load chain collecting box the fo llowing points should be borne in mind: (I) Chain is a load in itself and the uncontrolled fall of a length of chain

could inflict serious injury upon any personnel in its path, as well as subjecting the block to a high shock load. To avoid this risk a load chain collecting box must be properly designed for the job.

(2) It should be of adequate capacity for all the load chain when the bottom hook is in the highest possible position, ie when the block is fully drawn up. lf the box is of inadequate capacity, the chain wi ll spi ll over the edge

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and, rather like a siphon, once this occurs ALL the chain in the box will be pulled out at an accelerating rate. A box of inadequate capacity may also prevent the chain feeding properly into the load wheel causing a jam or even failure of the chain.

(3) Where moisture or condensation is likely, the box should be provided with a suitab le drainage hole to prevent a build up of water. Conos ion resistant materials should be used for the construction and attachment of the chain collecting box.

Note: The collecting box may be known by other terms such as bucket or bag as appropriate to the particular design.

Brake Mechanism The block should be fitted with an automatic brake capable of anesting and susta ining the load. It should function at all loads down to a minimum of 5% of the safe working load .

Slack Chain Anchorage The slack end anchorage for the load chain should be at least equal in strength to 2.5 times the maximum tension in the load chain when the safe working load is being lifted.

2.3 Types of lever hoists A number of different makes are cunently available and in addition some manufacturers produce more than one model. The following infonnation, although of a general nature, gives guidance on the main options.

Type of Chain Chain lever hoists are designed to employ one of two types of chain, fine tolerance (calibrated) round steel link chain or roller chain. Due to the potential corrosion problems, roller chain is unsuitable for use in the offshore environment.

Brake Mechanism The hoist should be fitted with an automatic brake capable of arresting and sustaining the load. It should function at all loads down to a minimum of 5% of the safe working load.

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Chain Retention The load chain should be fitted with a stop at the free end large enough to prevent it passing over the load wheel or with some other equally effective means of preventing the chain from mnning out. The stop should be capable of withstanding a load at least equal to 2.5 times the maximum tension in the load chain when the safe working load is being lifted.

2.4 Alternatives to Hand Chain Blocks and Lever Hoists One alternative to both items which should be cons idered, particularly for underwater applications or those in the splash zone, is the wire rope jaw winch. Some models have a degree of corrosion res istance and, although they all require adequate lubrication, they cannot be over lubricated and no components will suffer from contamination by lubricants.

If the app lication requires the load to be susta ined for a significant length of time between the lifting and lowering operations, cons ideration should be given to using other equipment to sustain the load as a block or hoist may cmTode during the sustaining period and be unsafe for a subsequent lifting or lowering part of the operation. For example the load can be ' tied off with a suitable wire rope sling. Alternatively consideration should be given to using fi"es h equipment to take the load before releasing the equipment which has been sustaining it.

2.5 Hazardous Conditions The following is a list of the most common conditions known to present a significant hazard and which may require special consideration when selecting equipment: ( 1) Underwater and where seabed contaminants are present. (2) Accelerated corrosion of components due to the matine/saliferous

conditions particu larly where both salt water and air are present, eg the splash zone.

(3) Where inflammable material could be ignited by a spark, particu larly in explosive or potentia lly explosive atmospheres.

(4) Near to a flare stack, turbine exhaust or hot condensate lines . (5) Exposed to temperatures outside of the range oo C to 25C. (6) Exposed to chemicals pat1icularly those likely to corrode meta ls and

ac idic environments eg drilling muds in the rig floor area . (7) Where movement of the vessel or install ation imposes additional

dynamic loads on the equipment.

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(8) When the load is low relative to the SWL and may be insufficient to properly operate the brake. Generally loads of less than 10% of the SWL should not be li fted.

Section 3 Information and data requirements 3.1 Legal commentary The essential legal requirements are: (1) The equipment must be safe and suitable for its intended purpose. (See

HSW A Section 2) (2) Manufacturers and suppliers must provide infonnation on the safe use of

their equipment. (See HSWA Section 6) (3) Those obtaining equipment for others to use must ensure it is safe and

suitable for the intended purpose. (See HSWA Section 4) (4) Employers must ensure that work equipment is on ly used for operations

for which, and under conditions for which it is suitable. (See PUWER Regu lation 4)

To achieve those objectives the equipment must be properly specified, supplied according to the specification, thoroughly examined before first use and accompanied by the infonnation requ ired to use it safely. In practice the specification is often decided jointly by the purchaser and the supplier. Sections 3.2, 3.4 and 3.4 identify the infonnation required and appendix C provides a model data sheet for this purpose. A proper and sufficient exchange of infonnation between the parties should exist in order that, at the outset, the correct and fit for purpose equ ipment can be supp lied.

3.2 Hand chain blocks - Information which should be provided by the equipment specifier As hand chain blocks are frequently used for miscellaneous lifting purposes, precise details of the load to be lifted are not always avai lab le. ln these circumstances only a general specification can be given and this should include the following infom1ation: (I) The safe working load. (2) The maximum extended dimension. (3) (4) (5)

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The maximum acceptab le drawn up dimension if headroom is important. The range oflift. The distance from the suspension level to the operating level. (This caters for the situation where a hand chain which is shmier than the load chain is required.)

(6) The conditions of service and in particular any conditions which the user suspects might be hazardous. See section 2.5 for guidance on known hazardous conditions.

(7) The type of suspension ie hook suspended or built into a trolley. In the case of blocks with a bui lt in trolley, the information required for the trolley is as follows: (a) Type of trolley. If the trolley is for use where the runway is liable to

tilt, eg due to roll of a vessel , the nature and amount of movement to be accommodated, whether movement under load is required and whether a means of locking in position is required.

(b) Details of the runway beam section to which the trolley is to be fitted. These details must be sufficient to fu lly identify the particular rolled steel section or in the case of a fabricated section, the various elements from which it is manufactured. In addition, details of fixing bolts, clips, splices etc are required to ensure that they will not foul the load bar, trolley wheels or anti-tilt device where fitted.

(c) If a geared trolley is specified, then the suspension and operating levels are required so that the length of hand chain may be detennined.

3.3 Chain lever hoists - Information which should be provided by the equipment specifier As chain lever hoists are frequently used for miscellaneous lifting purposes, precise details of the load to be lifted are not always available. In these circumstances only a general specification can be given and this should include the following information: (I) Intended application eg lifting, tensioning or pulling. (2) The safe working load. (3) The maximum extended dimension. (4) The maximum acceptable drawn up dimension if headroom is important. (5) The range of lift. (6) The conditions of service and in particular any conditions which the user

suspects might be hazardous See section 2.5 for guidance on known hazardous conditions.

3.4 Hand chain blocks and lever hoists - Information which should be provided by the supplier The following information should be provided to the purchaser and accompany the equipment to the end user:

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(I) Copy of the last LOLER report of thorough examination. (For new equipment this will be the report of thorough examination before first use - see 4.2 below)

(2) Instructions for use which should include the following infonnation: (a) General purpose instructions. (b) Any limitations or special requirements for use in hazardous

conditions.

Section 4 Thorough examination including verification testing 4.1 Legal commentary Regulation 9 of LOLER (Sl 2307) requires lifting equipment to the thoroughly examined before being taken into use for the first time, at intervals throughout its life and after exceptional circumstances which may jeopardise safety have occurred. The term ' thorough examination' includes any testing as is appropriate.

If equipment is transferred from one undertaking to another, as typically happens with hire equipment, the equipment must be accompanied by evidence that the last thorough examination required by this regulation has been carried out.

Regulation 9 permits some flexibility of the requirements depending upon the particular circumstances but for the purposes of this code, the good practice set out in 4.2 and 4.3 should be followed.

4.2 New equipment prior to supply Although LOLER provides an exemption for new unused equipment for which the employer has received an EC declaration of confonnity made out not more that 12 months before the equipment is taken into service, due to the exceptional conditions to which the equipment may be exposed, every block or hoist should be thoroughly examined before fust use, including a light load test and a proofload test.

The block or hoist should be examined by a competent person to check that it has been assembled correctly, the chain fitted conectly, the brake adjusted, that all fastenings are secure and that the slack end anchor or chain stop is in place and is adequate for its purpose.

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The light load test to verifY that the brake will sustain the minimum required load should be carried out with a load of2%- 5% of the SWL. The load should be raised and lowered through a height of between 250 mm and 500 mm. To be acceptable, when the hand chain or lever is released at any point during the raising and lowering, the brake should hold the load.

Note: Blocks which are fitted with sea ls may appear to hold the load by the brake, when in fact it is being held by seal friction only. This condition does not meet the acceptance criteria.

The proof load test should be carried out at the fo llowing loads: Up to 10 t SWL-150% ofthe SWL. l 0 t to 20 t SWL- SWL + 5 t over20 tSWL-125% ofSWL

The proof load may be applied by means of weights or hydraulically. If a hydraulic testing machine is used it should be of such a design that the block or hoist can be operated through the required distance whilst maintaining the proof load within an accuracy of -0 + I 0% of the required load.

The load should be lifted through such a height as will ensure that every part of the block or hoist mechanism and each tooth of the gearing comes under load. To be acceptable, the block or hoist should sustain the load and, after removing the load, the block or hoist should be visually examined and found free from defects.

Whilst operated under load, the block or hoist should operate smooth ly without excessive noise or jumping, particularly any arising from poor fit of the load chain in the load wheel pockets.

4.3 In-service equipment Although LOLER permits a maximum period between thorough examinations of twelve months, due to the exceptional conditions to which the equipment may be exposed, every block or hoist should be thoroughly examined at least every six months or placed in quarantine and thoroughly examined before being returned to service.

Prior to thorough examination the equipment should be subjected to thorough maintenance in accordance with 6.3 and all components examined tn

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accordance with 4.3 .I before being assembled and subjected to fina l test and examination.

4.3 .I Examination of components Prior to examination, the equipment should be stripped down to its component pat1S, the components cleaned and any conosion, paint etc removed in accordance with 6.3.

The components should be subjected to a visual examination canied out in good light and, if relying on artificial light, a good local source, such as a work bench light, should be avai lab le. The examiner should also have a magnifying glass avai lable .

For high stress critical components such as hooks, the examiner should have access to a suitable NDT processes, such as MPI or dye penetrant, which can detect fme surface cracks.

Some equipment has permanently assembled swivel hooks which cannot be dismantled for examination. Particular care must be taken when assessing the condition of the hidden bearing area. Comparison with a new hook will provide some indication of wear.

As well as checking the condition of the load chain and the load chain wheel , the examiner shou ld also check the fit of the two. This is best done with the loadwheel held in the hands and the load chain laid in place. The loadwheel is then rotated slowly to feed the chain. Any mismatch will be evident as the chain attempts to climb out of the wheel.

Check lists for the examination of b:ocks and hoists are appended to this code as appendix A and B respectively.

4.3.2 Test and examination After assembly, the block or hoist should be examined by a competent person to check that it has been assembled conectly, the chain fitted conectly, the brake adjusted, that all fastenings are secure and that the slack end anchor or chain stop is in place and is adequate for its purpose.

The block or hoist should then be subjected to a light load test and a safe working load operational test. In addition, if any untested load bearing spare parts have been fitted , it should be subjected to a proof load test. 14

The light load test to verify that the brake wi ll sustain the minimum required load should be carried out with a load of2%- 5% of the SWL. The load should be raised and lowered through a height of between 250 mrn and 500 mm. To be acceptable, when the hand chain or lever is released at any point during the raising and lowering, the brake should hold the load.

Note: Blocks which are fitted with seals may appear to hold the load by the brake, when in fact it is being held by seal friction only. This condition does not meet the acceptance criteria.

The proof load test should be carried out at the following loads: Up to 10 t SWL- 150% of the SWL I 0 t to 20 t SWL- SWL + 5 t over20 t SWL- 125% ofSWL

For both the safe working load operational test and the proof load test, the load should be lifted through such a height as wi ll ensure that every part of the block or hoist mechanism and each tooth of the gearing comes under load. To be acceptable, the block or hoist should sustain the load and, after removing the load, the block or hoist should be visually examined and found free from defects.

Whilst operated under load, the block or hoist should operate smoothly without excessive noise or jumping, particularly any aris ing from poor fit of the load chain in the load wheel pockets.

4.4 Records and reports 4.4.1 Internal job record A record of all tests and examinations related to the alpha/numeric identification of the equipment should be made contemporaneous with the work being done.

The record should identify the persons involved in the test and examination and show the work done by each, whether the equipment passed or fai led and be signed by those persons to authenticate their record.

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For examinations of the components of in-service equipment, the record should identify the person involved, whether the component passed or failed and be signed by that person to authenticate the record.

4.4.2 Report of thorough examination A report of thorough examination, based on and traceable to the record refened to in 4.4. 1, and containing the information spec ified in Schedule I of LOLER should be issued.

Appendix D provides a model fmm of report for this purpose but it is emphasised that this is only an example and any fonnat containing the specified u1fonnation is acceptable.

Section 5 Requirements for transportation, storage and control 5.1 Preparation of equipment prior to despatch The following steps should be taken to prepare the equ ipment prior to despatch offshore: (I) All band chain blocks and lever hoists should be thoroughly examined in

. accordance with section 4 of this code and have been found safe to operate.

(2) A report of the thorough examination containing the infonnation specified in Schedule I ofLOLER should be issued.

(3) The equipment should be prepared for shipment by wrapping and securing the chain(s) to prevent knotting/entanglement, placing it into a container or securing it to a pallet and protecting it from damage and corrosion eg by the use of a suitab le lubricant on chains and sluink wrapping.

(4) The law requires that equipment be accompanied by:

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(a) Physical evidence that the last thorough examination required by Regulation 9 of LOLER bas been canied out. (See LOLER Regulation 9) This should be complied with by providing a copy of the report of thorough examination in accordance with Schedule I ofLOLER;

(b) The instructions for use (See HSWA Section 6) . These shou ld be contained in a protective plastic sleeve and include this code. Note: If severa l items are despatched together, a separate copy of the code IS not necessary for every item.

(5) At the quayside or customer stores, if the equipment is unpacked for inspection, those responsible should ensure it is restored to its protected despatched state complete with documentation before onward shipment.

5.2 Transportation and storage conditions During transport to the offshore installation and whilst in store on the installation, the equipment should be protected from exposure to any conditions wnich may affect its ability to operate safely. In particular it should not be exposed to: (I) Water/sea water. (2) Temperatures higher than can be comfortably to lerated with the hand. (3) Temperatures below freezing point. (4) Solvents. (5) CotTosive chemicals or fumes. (6) Windblown dust, grit or sand.

The equipment should be stored in a purpose designated storage facility, eg a rigging loft, where it can be kept secure from unauthorised use. This may be either a transportab le containerised rigging loft or a controlled permanent stores. Uncontrolled stores or stores accessible by personnel not authorised to use lifting equipment should not be used.

The equipment should be stored on suitable racks in a manner wh ich prevents accidental mechanical damage.

The storage facility should include a secure quarantine area for storing equipment no longer fit for further service.

5.3 Management of issue and return to store In this section, the term 'nominated person' is used to identify a person who should be responsible for issue and return of equipment, inspection of equipment between thorough examinations to check whether it remains fit for service and some maintenance/repairs. It is not intended to restrict those responsibilities to a single person and it is recognised that, depending on the type of facility, staffing levels, sh ift patterns etc one or more people may. be involved. However in all cases the persons involved should be adequately trained fo r whatever pa1i of the work they undertake and any records shou ld identify the particular person involved. See also section 6 which uses the term in the same context.

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The storage facility should be controlled by a nominated person who is responsible for recording the issue and return of all equipment. No one other than the nominated person should be permitted to issue equipment from the store.

All equipment should have a unique alpha/numeric identification.

Within the equipment store there should be a documented record of the equipment containing the following information: ( 1) Alpha/numeric identification. (2) Description including:

make; model; SWL; height of lift;

and additionally for hand chain blocks: if not hook suspension, the type of suspension/trolley; if hand chain length not matched to load chain, the operating level height.

(3) Report number of relevant LOLER report of thorough examination. (4) Date, stated in report referred to in (3), by which the next thorough

examination must be carried out

There should also be available within the store area for reference a copy of the instructions for use of the equipment and a copy of this code.

The person wishing to obtain equipment from the store should have authorisation for the use of such equipment and should present it to the nominated person. The authorisation should give an estimate of the length of time the equipment will be reqnired. Equipment should not be issued unless authorisation is produced.

The nominated person should select the specified equipment, make a record, related to the above equipment record, showing the dates of issue for use and return of all equipment. The record should identifY the person and, if appropriate the department/contractor/location to whom tbe equipment is issued and be signed by the person to whom it is issued. It should also be signed by the nominated person at the time of issue to confirm that it is fit for service at the time of issue.

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If the specified equipment is not available, the person wishing to obtain the equipment should seek new authorisation for any alternative equipment. Alternative equipment should not be issued without authorisation.

There should be a clear instruction from the nominated person to the person obtaining the equipment that they are responsible for ensuring it is used only for the purpose for which it is authorised and retumed to the store after completing the job and that it should not be left unsecured or available for unauthorised persons to use.

ln the event of a shift or crew change whilst work is in progress, there should be a hand over procedure to fotmally pass responsibility on .

The nominated person should, so far as is reasonably practicable, actively monitor equipment taken from stores and not returned within the time estimated to ensure that it is not left unsecured or available for unauthorised persons to use and to take steps to recover it if it is so found.

On return to stores, the nominated person on duty should enquire whether there are any operational problems with it (eg brake slipping, not operating smoothly, jumping under load, excessive effort required), or whether it has been exposed to exceptional circumstances eg chemical contamination or overload. The person responsible for the equipment whilst it was in use should repot1 if such be the case and the nominated person should immediately label it as unfit for service and note the problem repot1ed. lf the problem cannot be rectified within the nominated person 's remit, it should be placed in the secure quarantine store immediately.

All other equipment returned to stores should be cleaned if required and inspected as detailed in section 5.5 by the nominated person and, if fit for service, returned to the available for use racks. Equipment found not fit for service should be labelled as unfit for service and placed in the secure quarantine store immediately.

If equipment carmot be cleaned and inspected at the time of return to stores, it should be labelled as awaiting inspection and placed in the secure quarantine store inunediately until such time as it can be done.

It is recommended that a visible record system, such as aT card system, is used to indicate the availability and serviceability status of all equipment in the

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store, equipment which bas been issued and is out of store and the dates of issue and return together with details of whom it was issued to and , if issued for use in hazardous conditions, the nature of those conditions.

5.4 Cleaning of equipment Equipment returned to store should be checked for contaminants and cleaned if necessary prior to inspection and further storage.

Equipment used sub-sea or which has been exposed to sea water splash/spray should be washed with fresh water without pressure. Pressurised jets should not be used as they can remove essential lubricants or cause them to migrate to brake components which should be fiee of lubricant.

After washing the equipment should be dried without the application of direct heat.

"Equipment should not be immersed into lubricant, diesel etc in an attempt to displace water as this will allow lubricant into the brake components.

The equipment should not be dismantled for cleaning except by an authorised competent person. However non-load bearing gear covers may be removed by suitably trained personnel to provide access to wash, dry and lubricate gears . Such covers should be replaced correctly immediately afterwards.

The load chain may be lubricated.

The pawl pivot and spring may be lubricated if clearly visible and accessible without dismantling. Care should be taken to avoid any lubricant entering the brake components and, as a precaution, before applying the lubricant the brake should be closed by operating the equipment in the hoisting direction.

For a list of suitable lubricants for the various parts of the equipment see section 6.4 Only these approved lubricants should be used. lf other types of lubricants have to be used, then this should only be done with the approval of the equipment supplier.

5.5 Inspection prior to and following use With the exception of equipment quarantined as unserviceable, all equipment in the store should previously have been inspected and found to be tit for

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service. At the time of issue from the store all equipment should be inspected by the nominated person to ensure it has not deteriorated during storage.

The equipment should therefore be checked for correct operation bearing in mind that some components may have seized due to corrosion. In particular the equipment should function freely and smoothly in both hoisting and lowering directions, the brake should engage and release smoothly, the ratchet pawl should operate freely and on lever hoists, the lever reversing pawl selector and hand wheel should operate freely.

On return to stores, after any cleaning and drying but before lubrication, the nominated person should inspect the equipment for defects arising from use in service. ln particular the following should be looked for:

Hand chain blocks (I) The load chain is worn or damaged. In particular, attention should be

given to the wear which occurs on the bearing surfaces inside of the links and to damage in the fonn of bent, notched, stretched or corroded links. The chain should articulate freely. In certain circumstances, very rapid wear of the load chain can develop, which is characterised by a rough appearance on mating surfaces inside ofthe links.

(2) The load chain sprocket should be checked for debris in the pockets . Any build up of debris will prevent the load chain from seating correctly and should be removed.

(3) Obvious signs of 'opening out' of hooks, that is any noticeable increase in the throat opening, or any other fonn of distortion in the hooks or suspension fittings.

( 4) Missing or damaged hook safety catch. (5) Obvious signs of damage to the slack end anchor which connects the load

chain to the block casing or to the load chain stop where one is fitted. (6) The hand chain is worn or damaged, particularly on the bearing surfaces on

the inside of the links, or is corroded, bearing in mind possible damage to the operative's hands.

(7) The alpha/numeric identification or the safe working load markings are not clearly visible.

(8) General damage to the block body, including any gear covers or chain guides.

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Lever hoist (I) The load chain is worn or damaged. In particular, attention should be

given to the wear which occurs on the bearing surfaces inside of the links and to damage in the fonn of bent, notched, stretched or corroded links. The chain should articulate freely. In certain circumstances, very rapid wear of link type load chain can develop which is characterised by a rough appearance on mating surfaces inside of the links.

(2) The load chain wheel should be checked for debris in the pockets . Any build up of debris will prevent the load chain from seating correctly and should be removed.

(3) Obvious signs of 'open ing out' of hooks, that is any noticeable increase in the throat opening, or any other fmm of distortion in the hooks or suspension fittings.

(4) Missing or damaged hook safety catch. (5) Obvious signs of damage to the load chain stop or the chain anchor which

connects the load chain to the lever hoist casing, whichever is applicable. (6) The alpha/numeric identification or the safe working load markings are not

clearly visible. (7) General damage to the lever hoist body, including any gear covers,

breaking of overload protection devices, conhols or chain guides, and in pa11icular to the operating lever which could indicate a previous overloading.

If any of the above are found they should be rectified if within the nominated person's remit.

Note: The remit should not permit the dismantling of the load bearing components of the equipment or of the brake. See section 5.1

If any of the above are found and cannot be rectified, the equipment should be labelled as unfit for service and placed in the secure quarantine store immediately.

If the person returning the equipment to the store reports that, when operated under load, there is any jumping or excessive noise of either the hand chain or load chain, any undue effort is required or any visible slipping of the brake, the equipment should be labelled as unfit for service and placed in the secure quarantine store immediately.

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The nominated person should make a signed and dated record of the inspection and any rectification work clearly indicating if the equipment is fit for further service.

5.6 Quarantine of unserviceable equipment Any equipment found not fit for further service for whatever reason should be labelled as unfit for service with reasons why and placed in the secure quarantine store inunediately.

Such equipment should not be issued for service under any circumstances until it has been repaired and subject to thorough examination by a competent person under the provisions of Regulation 9 of LOLER and a report, complying with Regulation I 0 and Schedule I of LOLER, has been issued stating that the equipment is safe to operate.

Equipment labelled as awaiting inspection may be returned to service if found fit for service following inspection by the nominated person.

Section 6 Maintenance 6.1 Legal commentary There is a general requirement in PUWER (SI 2306) Regulation 5 to ensure that work equipment is maintained in an efficient state, in efficient working order and in good repair. The efficiency and safety of hand chain blocks and chain lever hoists is very dependent upon:

(I) Them being free of contaminants and corrosion which cause components to seize.

(2) Them being suitably lubricated and the lubricant kept away from the brake.

(3) Components liable to wear and deterioration being replaced before their condition becomes dangerous .

In the offshore environment, all three of these matters requires regu lar attention. Whi lst basic maintenance and minor repairs can often be made at the storage facility, to deal with these matters adequately, the equipment should periodically be taken to a maintenance facility with suitable equipment and

tra in~d personnel who can carry out the work.

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6.2 Maintenance whilst in store offshore In this section, the term ' nominated person' is used to identify a person who should be responsible for issue and return of equipment, inspection of equipment between thorough examinations to check whether it remains fit for service and some maintenance/repairs. It is not intended to restrict those responsibilities to a single person and it is recognised that, depending on the type of facility, staffmg levels, shift patterns etc one or more people may be involved. However in all cases the persons involved should be adequately trained for whatever part of the work they undertake and any records should identify the particular person involved. See also section 5 which uses the term in the same context.

Any maintenance carried out whilst in store offshore should be under the control of the nominated person.

The nominated person should be given a clear written remit about what repairs may be undertaken by him without affecting the integrity of the equipment to the extent that it must undergo thorough examination.

The remit should not permit the dismantling of the load bearing components of the equipment or of the brake.

6.3 Periodic maintenance The fo llowing good practice should be followed:

6.3.1 Dismantling The equipment should always be stripped down to its component parts.

6.3 .2 Retention of identity

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The component parts for a particular block or hoist should retain their identity and not be mixed with similar components from other blocks or hoists. This is necessary to ensure an accurate history of the equipment and may be achieved by, for example, putting the parts into an individual storage box.

The manufacturer' s plate should not be removed. If it becomes damaged it should be replaced with a genuine spare and the information transferred. If a supplier's plate is fitted , it should be in addition to the manufacturer's plate.

6.3.3 Cleaning of components The components should be thoroughly cleaned by an appropriate process. The processes used should not be detrimental to the components nor should they tend to hide defects . Therefore, for example, acids must not be used as they may cause hydrogen embrittlement of chain. In general a chemical wash to remove lubricants and contaminants, followed by a light grit blast to remove paint and corrosion is appropriate although for chain, dry rumbling is preferred to grit blasting.

6.3.4 Examination of components Following cleaning the components should be visually examined for defects in accordance with 4.3 .I and any found faulty replaced.

If there is any doubt about the condition of the brake disks, new ones should be fitted.

6.3 .5 Quality of replacement components Any replacement components should be suitable for their purpose. In general , components should be to the same specification as those in the equipment when first supplied by the original equipment supplier unless subsequently superseded by components of improved specification which make them more suitable for use in the offshore environment, in which case the later specification should be used.

Particular care should be taken with brake disks as disks of comparable size and appearance may be made of different material and not perform to the same standard.

The load chain should be the correct grade, size and fit. The grade can be identified from manufacturer's marks on the links at intervals, generally every 20th link. As well as being of the correct nominal size, the pitch should also be checked as, for any given size, there may be small variations in pitch to match the chain to a particular design of pocket wheel.

The hand chain should also be of the correct size and fit.

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6.3.6 Treatment to resist corrosion and lubrication After examination and before assembly, the components to be used should be treated to resist corrosion and, where appropriate, lubricated. See section 6.4 for suitable lubricants.

The working faces of the brake should be left clean and dry and not treated or lubricated in any way. The volume of lubricant on other components should be such that it will not work or migrate from these components onto the faces of the brake unit under operational conditions.

In general, the surface of all other components liable to corrode should be treated.

Except for bearing surfaces, the frame or body of the block or hoist, both sides of all covers, the hand chain wheel or lever and the .top and bottom hooks should be painted.

All surfaces of gears and shafts and the bearing sutfaces of other components should be coated with a suitable lubricant to serve the dual purpose of protection and lubrication (see section 6.4 for suitable lubricants ).

For convenience of working, the chains may be lubricated after assembly.

6.3. 7 Records of maintenance and repair A record related to the alpha/numeric identification of the equipment should be kept of the maintenance and repairs done and any eomponents replaced.

The record should be made contemporaneous with the work being done.

6.4 Suitable lubricants The lubricants used should be chosen to suit the specific application if known. For all other applications, the following two types of lubricant should be used:

( l) A water tolerant grease suitable for gears and bearings and the temperature range likely to be found during shipment, storage and use .

For example Shell Alvania WR 2.

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(2) A wax based lubricant I corrosion protective product which can be applied by dipping or spray to the chains.

For example Shell Ens is SX.

COSHH data should be obtained for all lubricants used and, where necessary, control measures identified.

Section 7 Historical records 7.1 Records to be kept for the life of the equipment The EC declaration of conformity, cross referenced to the alpha/numeric identification of the equipment, should be kept by the owner of the equipment for so long as the equipment is available for use.

The instmctions for use provided by the manufacturer should also be kept by the owner of the equipment for so long as the equipment is availab le for use.

For equipment where safety depends upon the installed conditions, the report of thorough examination fo llowing installation which states that it has been installed correctly and is safe to operate should be kept by the employer until he ceases to use the equipment at the place it was installed.

7.2 Records to be kept for a limited period The following records cross referenced to the alpha/numeric identification of the equipment should be kept by the person responsible for making them for at least the periods shown:

Record ( l ) Report of thorough examination

(2) In-service issue and return

(3) In-service inspection record

Minimum Period Two years or until next such report is issued wh ichever is the longer

Until equipment is withdrawn from service for maintenance and thorough examination*

Until equipment is withdrawn from service for maintenance and thorough examination*

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(4) Maintenance record Two years or four maintenance periods whichever is the longer

For hire equipment transferred from one undertaking to another, the copy of the report of thorough examination referred to in 5.1(4)(a) shou ld be kept until the equipment is withdrawn from service or returned off hire.

*If the equipment has been withdrawn fiom service fo llowing an incident, these records should be retained until after the incident has been investigated.

Section 8 Planning the lifting operation and safe use of hand chain blocks and lever hoists The LEEA Code of Practice for the Safe Use of Lifting Equipment, edition 7 dated May 2009 provides general guidance on planning the lifting operation in Section I Appendix I. 7 and information for the safe use of hand operated chain blocks and lever hoists in sections 2 and 3 respectively.

Because of the number of different makes of blocks and hoists currently available, the information in the Code is of a general nature only and the limitations of use may vary from one make or model to another. Therefore in formu lating policy on safe use, the manufacturer' s instructions should always be taken into account.

The fo llowing restrictions on use should always apply:

(I) Never use equipment which does not have a current report of thorough examination, stating that it is safe to operate.

(2) Never use equipment that has been withdrawn fiom service and quarantined due to a defect.

(3) Always inspect the equipment before use and do not use it if any of the fo llowing defects are fo und:

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(a) The load chain is heavily corroded or damaged. In par1icular, attention should be given to damage in the form of bent, notched or stretched links. The chain should articu late fieely.

(b) Obvious signs of 'opening out' of hooks, that is any noticeab le mcrease rn the throat openmg often indicated by the position of the

safety latch, or any other form of distortion in the hooks or suspension fittings.

(c) Obvious signs of damage to the slack end anchor which connects the load chain to the block casing or to the load chain stop where one is fitted. The anchorage or load chain stop must be of at least equal strength as the chain to prevent accidental nm out.

(d) On a hand chain block, the band chain is corroded or damaged, bearing in mind possible injury to the operative's hands. On a lever hoist the operating lever is distorted which could indicate a previous overloading.

(e) General damage to the block or hoist body, including any gear covers, breaking of overload protection devices, controls or chain guides

(f) When operated under load there is any jumping or excessive noise of either the hand chain or lever or load chain, any undue effort is required or any visible slipping of the brake.

( 4) Never use the load chain to sling the load, ie do not wrap the chain around the load and back hook it or pass the chain through the load so that it lies across an edge or corner of the load. The load chain should always be free to take up a straight line under load.

(5) Ensure that tbe top arid bottom hooks are free to articulate in their respective connection points so that the block or hoist is free to take up a straight line under load.

(6) Never overload the equipment. If more than one block or hoist are used to lift or lower a load, the plan for the lifting operation should ensure that the load imposed on each is never more than its SWL. In particular care should be taken in planning the lowering operation when lowering on one block or hoist transfers the load to others.

(7) Never extend the handle of a lever hoist with a tube or similar implement to increase the leverage nor apply any method of power drive to a hand chain block or lever hoist. The majority of band chain blocks and lever hoists are designed to be capable of operation by a single person. lf it is

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found that additional effort is required then either the equipment is overloaded or is in need of maintenance and should be withdrawn from service. That is not to prec lude the use of two persons which may be found advantageous in some app lications but is to indicate the degree of operating effort nonnally required.

(8) Do not attempt to lift a load of less than 10% of the SWL of the hand chain block or lever hoist. This is because the brake relies on the torque generated by the load. Under test the brake is checked down to 5% of the SWL but prolonged storage and exposure to hot or cotTosive atmospheres can affect the efficiency of the brake.

(9) If equipment is to be left in place sustaining a load in environmental conditions where heat or rapid corrosion can occur, the li fttng plan should recognise that the brake may not function CO!Tectly or efficiently when the time comes to lower the load. Alternative methods of sustaining the load or the use of fresh equipment to take over and lower the load should always be considered.

Section 9 Training and competency 9.1 Legal Commentary There is a general duty on emp loyers under Section 2 of the Health and Safety at Work Act 1974 which includes:

"the provision of such infom1ation, instruction, training and supervision as is necessary to ensure, so far as is reasonably practicable, the health and safety at work of his employees"

Regu lation 8 ofLOLER requires:

{I) Eve1y employer shall ensure that eve1y lifting operation involving lifting equipment is-

{a) (b) {c)

properly planned by a competent person; appropriately supervised; and carried out in a safe manner

and paragraph 210 ofthe ACoP states:

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"21 0 The person p lanning the operation should have adequate practical and theoretical knowledge and experience of planning lifting operations."

The guidance recognises that the competent person required to cany out the planning is unlikely to be the same person refeiTed to in regulation 9. However, whilst the ACoP and gu idance give much useful advice about p lanning and canying out the lifting operation, it does not add much about the knowledge which the p lanner and the operatives should have. Section 9.2 below lists the essential knowledge each should have.

9.2 Essential knowledge for the planner and operatives The planner should be fami liar with : (I) Legislative requirements particularly:

(a) general duties of employees at work (b) duties of employers to employees (c) PUWER (d) LOLER (e) HSE Technical guidance on the safe use of li fting equipment

offshore ref HSG221 (2) Industry codes and guidance, pa11icularly:

(a) the LEEA code of practice for the safe use of li fting equipment (b) this code

(3) Principles of selecting blocks and hoists for use in the offshore envirol1111ent

(4) Princip les of risk assessment and duties in this respect under the Management of Health and Safety at Work Regulations 1999

(5) lnfom1ation to be contained in a lifting operation plan (6) Operative training requirements and operative registration schemes eg

SHE, SCAT (7) PPE requirements

The operative should be fami liar with: (I) Legislative requirements particularly the general duties of employees at

work (2) Industry codes and guidance, particularly:

(a) the LEEA code of practice for the safe use of lifting equipment (b) this code

(3) Control and issue procedures

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(4) Inspection procedures: (a) pre-use (b) post-use

(5) Reporting of equipment fa ults ( 6) Basic slinging practices (7) Methods of estab lishing:

(a) we ight of load (b) position ofC ofG (c) positioning and suitability oflifting points

(8) Reporting of inc idents and accidents

Regu lation 9 of LOLER requires that the thorough examination, including the appropriate testing, is carried out by a competent person. The term is not defined within the regu lations, but paragraph 294 of the ACoP states:

"294 You should ensure that the person carrying out a thorough examination has such appropriate practical and theoretical knowledge and experience of the lifting equipment to be thoroughly examined as wi ll enable them to detect defects or weaknesses and to assess their importance in relation to the safety and continued use of the lifting equipment."

Paragraph 295 of the guidance adds the following:

"295 It is essential that the competent person is sufficiently independent and impartial to a llow objective decisions to be made. This does not mean that competent persons must necessarily be employed from an external company. If employers and others within their own organisations have the necessary competence then they can use it. However, if they do, they must ensure that their ' in-house' examiners have the genuine authority and independence to ensure that examinations are properly carried out and that the necessary recommendations arising from them are made without fear or favour."

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Appendix A - Check list for thorough examination of band chain blocks

(I) Prior to examination, the equipment should be stripped down to its component parts, the components cleaned and any corrosion, paint etc removed in accordance with section 6.3.

(2) Hand wheel cover - examine cover for cracks, distortion and broken parts - check it allows free running of hand chain wheel

(3) Hand chain -examine hand chain for wear, nicks and corrosion - check pitch of hand chain in hand chain wheel

(4) Hand chain wheel - examine hand chain wheel for wear and damage - examine machined thread for wear and damage

(5) Brake assembly - examine splines, threads and ratchet teeth for wear and damage - examine brake component surfaces and ensure they are smooth and flat - check fit of ratchet ring bush and screw~d sleeve - check condition of pawls and pawl springs and ensure pawls operate

freely - check brake discs and, if in doubt, replace with new

( 6) Load chain dead end anchor pin - examine anchor pin(s) and links for strength, security, distortion and

wear (note that this should be at least equal in strength to 2.5 times the tension in the load chain at SWL)

(7) Bottom hook -examine load pin for distortion and wear -check that the hook swivels freely and there is no excessive wear on the

shank - check hook for stretch, distortion and wear - check that safety latch is present and operates correctly

(8) Gear cover -examine for cracks, distortion and broken parts

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(9) Spur gears, drive pinion and shaft - examine all gears for wear, fracture and alignment -examine drive pinion for damage and distortion - check shaft for straightness

(1 0) Load chain - check that chain is of correct grade (normally embossed every 20th link) - examine and measure load chain checking for bent, notched, stretched,

wom or corroded links

(11) Intemal fiame side plates - examine body plates for alignment and ensure they are free from wear

and distortion - examine load pin holes for signs of wear and stretch - where applicable, check top hook yoke and cross bar for wear and

distortion

(12) Top hook - examine load pin for distortion and wear - check that the hook swivels freely and there is no excessive wear on the

shank - check hook for stretch, distortion and wear - check that safety latch is present and operates correctly

(13) Chain rollers , chain guide and chain shipper -examine chain roller and pin for wear and damage - examine chain guide for wear and damage - examine chain stripper for wear and damage

(14) Load chain pocket wheel - check load chain pockets for wear and damage, ensuring satisfact01y

seating of load chain in pockets

( 15) Bearings - examine all bearings I bushes for wear - check smoothness of operation

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(16) Mu lti-fall blocks - check all load chain reeving sprockets for wear and ensure they rotates

free ly - check all associated bearings and pins - check all sprocket frames for wear, damage and distortion

(17) General - check that all components are suitable for their purpose and have not

been replaced by inadequate substitutes

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Appendix B - Check list for the thorough examination of lever hoists

(I) Prior to examination, the equipment should be stripped down to its component parts, the co.mponents cleaned and any conosion, paint etc removed in accordance with section 6.3.

(2) Lever assembly - examine lever and hand wheel for cracks, distmtion and broken pa1ts - check conect operation of pawl changing mechanism - examine pawl for wear - examine fit of pawl to stud - examine pawl springs for corros ion and fractures

(3) Brake assembly - examine splines, threads and ratchet teeth for wear and damage - examine brake component surfaces and ensure they are smooth and flat - check fit of ratchet ring bush and screwed sleeve - check condition of pawls and pawl springs and ensure pawls operate

free ly - check brake discs and, if in doubt, replace with new

( 4) Load chain dead end ring or stopper examine anchor ring or stopper for strength, security, distortion and wear (note that this should be at least equal in strength to 2.5 times the tension in the load chain at SWL)

(5) Bottom hook - examine load pin for distortion and wear - check that the hook swivels free ly and there is no excess ive wear on the

shank - check hook for stretch, distortion and wear - check that safety latch is present and operates conectly

(6) Gear cover - examine for cracks, distortion and broken pa1ts

(7) Spur gears, drive pinion and shaft - examine all gears for wear, fracture and alignment -examine drive pinion for damage and distortion - check shaft for straightness

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(8) Load chain -check that chain is of correct grade (normally embossed every 20th link) - examine and measure load chain checking for bent, notched, stretched,

worn or corroded links

(9) Internal frame side plates - examine body plates for alignment and ensure they are free from wear

and distortion - examine load pin holes for signs of wear and stretch - where applicable, check top hook yoke and cross bar for wear and

di stortion

( l 0) Top hook - examine load pin for distortion and wear - check that the hook swivels freely and there is no excess ive wear on the

shank - check hook for stretch, distortion and wear - check that safety latch is present and operates correctly

(11) Chain rollers, chain guide and chain stripper - examine chain roller and pin for wear and damage - examine chain guide for wear and damage - examine chain stripper for wear and damage

( 12) Load chain pocket wheel - check load chain pockets for wear and damage, ensuring satisfactory

seating ofload chain in pockets

(13) Bearings - examine all bearings I bushes for wear - check smoothness of operation

( 14) Multi-fall hoists - check all load chain reeving sprockets for wear and ensure they rotates

freely - check all associated bearings and pins - check all sprocket frames for wear, damage and distortion

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(15) General - check that all components are su itable for their purpose and have not

been replaced by inadequate substitutes

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Appendix C - Model data sheet to identify equipment required and conditions of use

It is recommended that a data sheet is used to specify the equipment required. The following model data sheet can be used by the enquirer/purchaser to specify and obtain the information referred to in sections 3.2, 3.3 and 3.4 and by the supplier to specify what is offered for sale or hire including any limitations on its use and special maintenance requirements. Additional infonnation such as dates, enquiry or purchase order numbers, documentary requirements, signatures of acceptance/approval etc may be added as required.

Technical and Operational Requirements to be Specified by the Enquirer or Purchaser The Equipment Required Hand Chain Block Lever Hoist Safe workino load tonnes tonnes Minimum A dimension required metres metres Maximum B dimension required metres metres Minimum C dimension required metres metres D dimension required metres Built in trolley required (if yes, Yes I I No I state type and beam section)

Chain box required Yes I I No I Overload orotection required Yes I I No I Yes I I No I The Location and Conditions of Use Site RiQ Platform Mono hull Zone explosive rating Non-hazardous Zone 1 Zone2 Operating temperature Below so C so c to 30 C Above 30 C Operatina zone Sub-sea I I Splash zone I I Drilling fioor I I Dry location I

Equipment proposed by the supplier Name of supplier Make 1 I Model I Ito number I Limitations of use

Special requirements

39

I I I I I I I I I exle~ded I I I dimension I I I I c I I range I I of lift '-../

/

40

Appendix D - Model report of thorough examination of lifting equipment

REPORT OF A THOROUGH EXAMINATION OF LIFTING EQUIPMENT This report complies with the LiftinQ Operations and LiftinQ Equipment Requlations 1998

Date of thorough examination: I Date of report: Report number:

Name and address of employer for whom the thorough examination was made:

Add ress of premises at which the examination was made:

Description and identification of the Safe working Date of Date of last equ ipment: load(s): manufacture if thorough

known: examination :

Is th is the first examination after installation or after assembly at a new site or location?

YES NO

If the answer to the above question is YES, has the equipment been installed correctly?

YES NO

Was the examination carried out: with in an interval of 6 months? YES NO within an interval of 12 months? YES NO in accordance with an examination scheme? YES NO after the occurrence of exceptional circumstances? YES NO Identification of any part found to have a defect which is or could become a danger to persons and a description of the defect: (If none state NONE)

Is the above a defect which is of immediate danger to persons?

YES NO

~a~;e~~g~~~g;!~ct(~~~~ i~t~?~ (~~ ~~t;~~~~~~g)me a YES by: NO Particulars of any repair , renewal or alteration required to remedy the defect identified above:

Particulars of any tests carried out as part of the examination: (If none state NONE)

IS THIS EQUIPMENT SAFE TO OPERATE? YES NO Name of the person making this report:

Name of the person authenticating this report:

Latest date by which next thorough examination must be ca rried out:

Signature: Name and address of employer of persons making and authenticating this report:

XYZ Lifting Equipment Co Ltd, Any Street, Any Town, Any County

4 1

120120409180744807