STANDARD OPERATING PROCEDURE SOP Number
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MOBILE CRANE INSPECTION SOP-004/BKI/CIT/10
Rev. Number Issued Effective
Chevron Kalimantan Operation 01 June 15, 2011 June 17, 2011
MOBILE CRANE INSPECTION
Facility/Section:
Area/Dept.:
Rev. Rev. Date Description Prepared by Reviewed by Approved by
Number BKI Team CICo. CICo.
New Issue
June 15, Whole
01 ___________ ___________________
2011 Document
Partial
Operational
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Excellence
Management
Chevron
System
Kalimantan
Operation
1 STANDARD AND SPECIFICATION
- IBU Lifting and rigging standard
- ANSI B30.5 Mobile and locomotive crane
- ANSI B30.8 Floating cranes and floating derricks
- ANSI B30.15 Mobile hydraulic crane
- ANSI B30.10 Hooks
- Other code and Standard
2 GENERAL DESCRIPTION
This procedure covers the requirements for annual inspection of mobile crane and to give
direction of inspector to carried out the inspection
3 SCOPE OF INSPECTION
1. Document Review
2. Visual and Dimension Check
3. Function test
4. NDT (Non Destructive Test) before and after load test
4 HES NOTICE
Some possibility of personal injury may occur before and during activities. The inspector has injury
possibilities to i.e. finger pinch, back injury and falling down.
5 PROCEDURAL STEPS
Action Remark
Action
Number (who & when)
I. Preparation
1 Prepared Work Permit and inquiry for approval BKI
2 Conduct safety talk, and determine specific job BKI
3 Prepared tools, NDT equipment, and PPE BKI
II. Execution
Evaluate working area to ensure that its area is safe during
1 BKI
perform the job
INSPECTION ;
2.1. Structure
2.1.1. Lattice boom
- Visual check and dimensional measurement
for length of boom
- Check pin / pivot boom
- Check condition of boom for bent, dent and
corroded members.
2.1.2. Telescopic Boom
- Check condition of boom for bent, dent,
corroded members and leakage on tube or
hose
- Check accomplished of extension and
retraction of boom section
2 BKI
2.1.3. Boom Hoist
Boom hoist may be a rope drum and its drive or
hydraulic cylinder the supporting mechanism may
be a gantry or the same hydraulic cylinder used to
elevate the boom
- Check for sign of crack, bend and corroded
members
- For hydraulic cylinder boom check the holding
devices (load check valve) check for leaking
on tube of hose of hydraulic system
2.1.4. Carrier
- Check of the crawlers (when applicable)
Condition and adjustment of roller chain drive,
looses or missing pin, lubrication
- Check condition of the tires (when applicable)
Check damage or excessive worn, tire air
pressure, wheel axis bearing and lubrication
- Check travel steering, braking and locking
device for mal function
2.2. Drum
- All drum shall provide a first layer rope pith diameter
of not less than 18 times of the nominal rope diameter
used
- The flange shall extend a minimum of ½” (13mm)
over the top layer of rope all times
- No less than two (2) full wraps of rope shall remain on
the drum in any operating condition
- The drum end of the rope shall be anchored to the
drum by an arrangement specified by the crane
manufacturer.
2.3. Brake and Clutches
- Check the control mechanism of brakes and clutches
for proper operations
- Check for leakage and damage in air and hydraulic
system
- Verify condition of all braking system
2.4. Prime mover
- Check prime mover for proper performance and
compliance with safety requirements
- Check condition of radiator
- Check belt or chains for proper adjustment
- Check all fluid level
- Check exhaust system, exhaust shall be equipped
with spark arresting devices, exhaust gasses shall be
piped to the outside of the engine enclosure and
discharged in a direction away from the operator
2.5. Wire rope
- Visually all wire rope for deterioration and damage
such as kinking, bird caging, crushing, corroded or
broken at the end connections
- Check that it correct size and rope is properly fitted
- Wire rope tester (electromagnetic inspection) shall
carried out over the length of the wire rope
- Replacement of wire rope
Running ropes ; six (6) randomly distributed
broken wires within one (1) lay length. Three (3)
broken wires in one (1) strand within one (1) lay
length
Standing rope such as pendants; More than two
(2) broken wires at the end connection
Wear of one-third the original diameter of outside
individual wires
Kinking, crushing ,bird caging, or any other
damage resulting in distortion of rope structure
Evidence of heat damage from any cause
Reductions from nominal diameter greater than
those listed below ;
- (a) 1⁄64” (0.4 mm) for diameters up to and
including 5⁄16 “ (8.0 mm)
- (b) 1⁄32” (0.8 mm) for diameters from 3⁄8
“.(9.5mm) to and including 1⁄2”(13.0mm)
- (c) 3⁄64” (1.2 mm) for diameters from 9⁄16”
(14.5mm) to and including 3⁄4” (19.0 mm)
- (d) 1⁄16” (1.6 mm) for diameters from 7⁄8
“(22.0mm) to and including 11⁄8” (29.0 mm)
- (e) 3⁄32” (2.4 mm) for diameters from 11⁄4 “(32.0
mm) to and including 11⁄2 “(38.0mm)
2.6. Wedge Socket
- Verify that the socket and wedge are correct size for
the rope in used
- Check the socket eye and pin for roundness and wear
A pin Keeper should always use with the pin
- Check socket and wedge for rough edges or burn
- Wire rope clips used in conjunction with wedge
sockets shall be attached only to the unloaded (dead
end) of the rope
- Ensure that the live end of the rope is on the straight
side of the socket and dead end on the tapered side
of the socket ( see ASME B30.5 )
2.7. Hook
- Hook shall be discarded where throat opening is 15
% more than original throat opening and also bending
or twisted more than 10 deg from plane of the unbent
hook
- Any wear exceeding 10% of the original section
dimension of the hook or its load pin
- Check condition of safety latch
- Repair by welding or reshaping are not recommended
2.8. Sheaves
- Check sheaves for Wear and corrugation , broken or
chipped flange, crack in the hub, freely rotating
without drag
- Check of dimension sheaves groove with sheaves
gauge
- Make sure the sheaves shall comply with diameter
wire rope to be used
- All Sheaves including running block should be
provided with guards or suitable devices to prevent
the rope from coming out of the sheaves groove
- Sheave Sizes:
(a) Boom-hoisting sheaves shall have pitch diameters
of not less than 15 times the nominal diameter
of the rope used.
(b) Load-hoisting sheaves shall have pitch diameters
not less than 18 times the nominal diameter of the
rope used.
(c) Load block (lower) sheaves shall have pitch
diameters not less than 16 times the nominal
diameter of the rope used.
2.9. Hydraulic System
- Visually check hydraulic pump, oil tank, hydraulic
hose, fitting and tubing from leakage and damage
2.10. Swing Mechanism
- Visually check for cracking and deformation, check
for excessive wear components
- Check the parking brake and shall be capable of
remaining in the engaged position without attention
of the operator
- Swing lock ( when provide ) shall be constructed to
with stand maximum swing torque developed by the
swing mechanism, prevent accidental engagement
or disengagement and shall be controllable by the
operator at his station
2.11. Out Rigger
- Check condition of out riggers when it is not
operated
- Check condition of out riggers when the load to be
handled at that particular radius exceeds the rated
load
2.12. Controls and Cabs
- Check the control operations and functions shall be
clearly marked and easily visible
- Control levers for boom hoist, load hoist, swing and
boom telescope (when applicable) shall return
automatically to their centre (neutral) position on
release
- Check condition of door, window, platform and
walkways
- Load chart shall be provide inside the cabs
- Function check of the Safety device such as, boom
hoist limiter, anti two block, overload protective
device, ESD
- Check the counter weight (when applicable) should
be ensure the correct configuration and all securing
bolts or pins are in place
- Fire extinguisher shall be provide in cabs operator
Non Destructive Test(NDT)
- Perform NDT of Hook and wedge socket
3 - If required NDT 10 % of boom (lattice) every annually BKI
inspection
- Perform wire rope test
Testing
Operating and function test shall include the following:
- Load hoisting and lowering mechanism
- Boom hoisting and lowering mechanism
4 - Safety devices such as Anti two block, Boom hoist limit, BKI
load limit devices, ESD, Alarm or horn
- Check function of load indicator, boom angle indicator for
accuracy
- Perform all braking system
Load Test (if required)
1.1. Dynamic test
Each crane should be given a dynamic test to ensure
crane capacity, dynamic testing should include the
following crane capacity:
- Hoisting and lowering load with 25%,50% and 100% of
Safe Working Load (SWL)
- Swing in range 1800 with carrying load as much 25%,
5 50% and 100% of Safe Working Load (SWL) or as per BKI
load chart table.
1.2. Static load test
The purpose of the static load test to verify that the
structure and other components are still good condition,
the static load shall not exceed 110% of the rated
capacity.
During load test load indicator should be verify with the
actual load.
Inspection after Testing
Purpose of inspection is to verify and ensure the condition of
6 the crane after load test BKI
- Visual inspection such as structure, wire rope, bolted and
welding connection, etc
- NDT for critical area, Hook and Wedge socket.
Reporting
Any defects or deficiencies of the crane found either during
7 inspection or after completed, should be discussed with the BKI
owner/user, and if necessary recommend corrective action.
Report consist of :
1. Certificate of inspection
2. Check list
3. Finding inspection
4. NDT report and dimensional check report
5. Wire rope test record
6. Load test report
7. Load indicator verification report ( if load test required )
III Completion
1 House Keeping BKI
2 Close out Work Permit BKI
