Q-1, as chief officer what are the checking s that you should carry out before using lifting gear? (Risk assessment and risk management)

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1 Lifting Gears Q-1, as chief officer what are the checking s that you should carry out before using lifting gear? (Risk assessment and risk management) Make sure that ship s lifting gear and associate equipments which involving loading and discharging activities are 100% operational and free of defects and all the valid certificates are readily available on board All the maintenances are carried out as per the PMS and records are readily available. Pre-checks to be carried out before commence the operation, such as, 1-any hydraulic oil leak and correct oil levels are maintained in the equipments. 2-any worn or damage wires are existing 3-any places with excessive corrosion 4-any cracking at welded areas present 5-any markings which supposed to display is missing from the cargo gears. 6-All control units Joysticks, Alarms, Limit switches, must be checked prior to use and all control must be operated before attaching the slings or grabs to the crane or derrick. Do the Risk Assessment (RA): it is the process of evaluating the probability and consequences of an injury or illness from exposure to an identified hazard and determining the appropriate measures for risk control. As such, there are three basic steps to RA. Step 1 - Hazard Identification Identifying the hazards associated with each work activity and the type of potential accidents/ incidents that can result from the hazards is the first step to RA. Some of the hazards associated with lifting operations such as poorly maintained wire ropes ECT... Step 2 - Risk Evaluation Risk evaluation is the process of estimating the severity of an injury or damage and the likelihood of the occurrence. For example, the risk level of workers working underneath a suspended pre-cast component should be assessed as a high risk hazard as the consequences of the load dropping can result in killing the workers underneath. Step 3 - Risk Control and Management This is a critical last step as it identifies appropriate risk control measures to reduce the risk level to an acceptable level. Following from the previous example of a suspended pre-cast component, an appropriate 1

2 risk control measure will be to prohibit workers from working directly underneath a suspended load. The lifting zone should also be demarcated to prevent any unauthorized entry. Q-2, what are the precautions that you should take before using lifting gears? Risk assessment was done with all crew who engaging in works well understood about the particular operations and permit to work forms filled and all are signed. Relevant cargo gears checked and all in order and all document proofs are readily available. All rigging plan requirements and cargo appliances are inspected. Ensure that lifting plan is made and discuss with the dock workers authority and acknowledge. Keep one copy for your reference Make sure that stability conditions are perfectly all right for cargo operation Ensure that UKC is well enough for cargo operation with heeling moment. Engine room was informed regarding cargo operation and power is available. Communication between ships personal who engaging in cargo work are tested. Q-3, what is the rigging plan and what is the purpose of it? A booklet from official document, which gives detail of cargo gear and lifting alliances. Every vessel with derrick and creams must have a rigging plan. The rigging plan consist of following information Position and size of the deep eye plate Position of in bound and out bound booms Maximum head room ( the permissible height of cargo hook above hatch coaming) Maximum angle between runners Position, size and SWL of blocks Length, size, and SWL of runners, topping lifts, guys and preventers SWL of s hackles Position of derricks producing maximum forces Optimum position for guys and preventers to resist such maximum forces Combined load diagram showing forces for load of 1 ton 2

3 Guidelines on the maintenance of the derrick rig Q-4, why lifting gear have to be tested? Certification of a vessels lifting appliances is enforced by the national authorities, i.e. port state and frequently also the vessels flag state. The certification has to comply with the ILO Convention No.152 which covers safety in lifting operations. The convention requires the certifications to be carried out by a competent person/body. An increasing number of national authorities now require that this commission is performed by classification societies. (Ships deck cranes, engine room cranes, and lifting equipment are examined in accordance with: - The Merchant Shipping Regulations - Flag state requirements - International Labour Organization (ILO) Convention 152, where it applies) Q-5, Describe the testing frequency of lifting gears. Before new equipment is taken into service At set periods as required by national regulations, typically every five years After structural modification and repair. Q-6, what is the proof load and why proof load test is done? Tests should be done using a weight, sufficient to ensure that when it is loaded to SWL. It will safely hold the load. As a gear cannot test for its breaking stresses, it is tested for weight above SWL, but less than breaking stress. That Load is called Proof load. Q-7, what are the factors governing proof load? (How do you determine what proof load to be used?) The Proof load depends on the component and its size. Every lifting appliance shall be tested with a test load which shall exceed the SWL. It is given in the ILO Convention 152. SWL up to 20t SWL 20t 50t SWL greater than 50t : 25% in excess of the SWL : add 5t to SWL : 10% to SWL 3

4 Q-8, Explain how to carry out proof test on your cargo gear. Let Assume... A crane on board with SWL 20 tons and need to carry out a proof test. As per the regulation, (ILO Convention 152) if the SWL of the crane is 20tons the excess amount to add is 25% of the SWL. So it needs to suspend a weight of 25tons to check the proof load. Let s do it with the water bags. Initially fill the water up to the required amount here 25 tons measured by dynamometer or from rate of flow of the water to the bag. Then crane will hang it for the 5min time period as per the regulation. Once the crane is capable of hanging the weight (SWL+25% of SWL) for the 5 min period, crane is pass the proof load test. Q-9, Compare the Dynamic test, Static test and Proof load test. Dynamic test Static test Proof load test By lifting the proof load By using a dynamometer When weight is hanging and swinging the load secured to the lifting point the boom shall be test for through the derrick or cranes operating arc as per the ship s rigging plan. of the rig and the anchored position on the deck. Increase the pull by using lifting point until the proof load is reached. Resetting can be done by this method. minimum, maximum and intermediate radius. 4

5 Q-10, during the proof load test of your cargo gear, what are the areas that the surveyor is expected to examine in addition to carry out dynamic test or static test. The maximum lifting and the minimum lowering angles settings. Q-11, after proof load test the surveyor will issue a test certificate. What is the validity period of test certificate and describe the content of it? The certificate will issue for the period of five years. The contents are, Equipment name/quantity Load applied Rated load Date Place Official stamp Signature of the surveyor Q-12, Describe what is the annual thorough examination of a cargo gear. Thorough Examination by a competent person once in every 12 month after any substantial alteration or renewal or after repair of any stress bearing part before being brought into use for the first time, unless it has been accompanied by valid regulatory documentation or report of thorough examination; where a regulatory requirement was received more than six months before the lifting equipment is put into service, or as the relevant regulator requires; where the equipment is involved in an accident or dangerous occurrence; after a significant change in conditions of use for example after installation/assembly/relocation/modification/repair; after long periods out of use; in the case of lifting equipment for lifting persons at intervals not exceeding six (6) months; Each time that an exceptional circumstance (such as overload) is liable to jeopardize the safety of the lifting equipment. The following items/areas will be thoroughly checked Visual inspection of the crane structure for deformation, excessive wear, corrosion, damage or fractures as necessary. The boom is lowered for this examination. 5

6 Visual inspection of crane hooks for deformation, excessive wear or fractures. For cranes intended for transfer of personal, non destructive testing of crane hooks for fractures. Visual external examination and operational test of crane machinery including prime mover, clutches, brakes, hoisting, slewing, and luffing machinery. Visual inspection of wire rope and end attachment Functional test of including mail and auxiliary load hoisting and lowering, boom rising and lowering, safety protective and limiting devices and angle or radius indicators. Q-13, how do you know if annual thorough examination has been done if you a new chief officer of the vessel. By inspecting the chin register as last inspection report and certificates shall be filled in the chain register. Q-14, what are the parts that you are going to inspect during your annual thorough examination? Visual inspection of the crane structure for deformation, excessive wear, corrosion, damage or fractures as necessary. The boom is lowered for this examination Visual inspection of crane hooks for deformation, excessive wear or fractures. For cranes intended for transfer of personal, non destructive testing of crane hooks for fractures. Visual external examination and operational test of crane machinery including prime mover, clutches, brakes, hoisting, slewing, and luffing machinery. Visual inspection of wire rope and end attachment Functional test of including mail and auxiliary load hoisting and lowering, boom rising and lowering, safety protective and limiting devices and angle or radius indicators. 6

7 Q-15, describe cargo gear booklet sometime known as register of lifting appliances That is the official document carrying onboard regarding lifting gears on board. It contains all the certificates and relevant document which readily available for inspections for authorities. 12 month thorough inspection, 5 year inspection also damages, repairs, alterations and replacements will be recorded here. Q-16, as chief officer you are to follow a planned maintenance system on board a ship. Describe how you carry out your planned maintenance system. Follow the maintained of equipments as per the manufactures instruction and as instructed by Company SMS system. So maintain all the monthly checks and maintenance reports in PMS system. These includes monthly greasing and lubrication of equipments also trying out of various equipments, bilges and inspection of tanks ect, at the end of the month a cop of PMS records shall be send to the office. Q-17, (a)-under ILO labor safety requirement what care would take on your cargo handling gear before same is utilizes for the purpose. (b)-what are the documental records you will provisional with regard to the lifting appliances on board for inspection by safety officer. (c)-a gun tackle reeves to disadvantage is used to lift a weight of 45T. The hauling part of the purchase is secured to the block of a single whip rigged to advantage. The velocity ratio of the system is equal to the product of the individual velocity ratio. Find the effort required to lift the weight and the efficiency of the system. Consider the rig is frictionless and weightless. (d)-a gun tackle reeves to Disadvantage is used to lift a 10T.The hauling part of the purchases secured to another gun tackle rigged to Advantage. The velocity of the ratio of the system is equal to the product of the individual velocity ratio. Find the effort required to lift this weight and efficiency of the system. Consider the rig is frictionless and weightless. A-(a), All the lifting gears and attachments must be checked before and during and after use All attachments gears must be inspected thoroughly and recorded every 12 months. 7

8 (b)- The entry must be made in the chain register or cargo gear book of lifting appliances. This should be done by the class surveyor. In addition chief officer must enter inspection detail in the cargo maintain booklet. All wire ropes must be inspected throughout the length. Of any length of 8 times its diameter has more than 10% of visible broken wires from the total number of wires in the rope. No person under 18 years of age and no person who is not competent should not be allowed to drive or operate lifting gear. No wire ropes should be used for hoisting or lowering unless it has a test certificate. The test certificated and reports shall be kept on board for inspection by any authorized person. 12 month thorough examination shall be recorded in the lifting appliances book (chain register) All list of certificated of wire and ropes also loose gears shall be attached to the back cover of chain registry. Cargo gear plan maintenance system (PMS) shall be up dated and available for inspection. Updated rigging plan shall be available for inspections. (c)- Gun tackles rig to disadvantage Standing block VR=2 D advantage Advantage Moving block Load 45T VR=1+1 hauling part Single whip rig to advantage 8

9 V.R. = distance travelled by effort/corresponding distance travelled by load Velocity Ratio = number of parts of the moving block M.A.=load/effort, (W/S) Efficiency = M.A. / V.R. Rig to advantage: when the load move in the same direction as the effort moves, In this case hauling part comes away from the moving block. Velocity Ratio = n+1 (n is the no: of sleeves in the purchase) Rig to disadvantage: when the load moves in the opposite direction to the effort. In this case the hauling part comes away from the fixed or standing block. Velocity Ratio = n (n is the no: of sleeves in the purchase) In above calculation, VR of the gun tackle which rig to disadvantage = 2 VR of the single whip rig to advantage (n+1) = 1+1 Total VR of the system = 4 Effort(S) = weight+ (nwf %) /VR (n-number of sleeves, w-weight, f-friction) (Consider weightless and frictionless) (Effort) S M.A. =45+(0)/2x2 =11.25t =W/S, =45/11.25 =4t Efficiency = (M.A./V.R.)x100 = 4/4x100 9 = 100%

10 Note: How to rig a gun tackle for advantage Hauling part VR=2+1 W (d) Here gun tackle reeves to disadvantages and another gun tackle is rigged to advantages Standing block Disadvantage VR=2 Moving Block Moving block Advantage 10 VR=2+1 Standing block 10

Effort (S) = W+(nwf%) / V.R. = 10(0) / 2+ (2+1) = 1.67 M.A. = 10/1.6667 = 6 Efficiency = 6/6x100 = 100% Q-18, (a) Sketch and label a common union purchase used on general cargo vessel.

11 Effort (S) = W+(nwf%) / V.R. = 10(0) / 2+ (2+1) = 1.67 M.A. = 10/ = 6 Efficiency = 6/6x100 = 100% Q-18, (a) Sketch and label a common union purchase used on general cargo vessel. (b)-describe in numerical order the rigging procedure of union purchase. (c)-what are the precautions officers of the ship should observe when using union purchase system for cargo operation. (d) What are the advantages and disadvantages of this system compare to crane and a single swing derrick. A= (a) see the below picture 11

1.portal mast (or portal derrick post), 2.cross tree (or upper transverse beam), 3.derrick boom positioned over the hatch (inboard boom), 4.derrick boom positioned outside the ship (outboard boom), 5.

12 1.portal mast (or portal derrick post), 2.cross tree (or upper transverse beam), 3.derrick boom positioned over the hatch (inboard boom), 4.derrick boom positioned outside the ship (outboard boom), 5.derrick heel gooseneck fitting, 6.derrick head fitting, 7.cargo winches, 8.cargo runners (or married falls), 9.cargo triangle plate, 10.cargo hook, 11.slings, 12. fixed (or standing) span ropes, 13.mast head span fitting,), 14.schooner guy tackle (or boom head guy tackle 15.preventer (or standing) guys, 16.slewing guy tackles (or vang tackles), 17.upper slewing guy pendants, 18.lower slewing guy pendants 19.belaying (or horn) cleat, 20.deck eyeplates 12

13 (b)-the most common derrick system in use on general cargo ships. In this method, Two derricks are joined by a union hook and worked in unison with each other. At the bottom end each derrick is joined to the vertical mast by a swivel fitting known as a gooseneck The up and down movement or luffing movement of the derrick is carried out by topping/span tackle The athwartship moment is control by a slewing guy attached to the out board side of the boom head. A guy called schooner guy (centre guy) which runs from the inboard side of one boom head to the other and then to the deck via a lead block on the mast, link the two booms. This guy is always clear of the cargo working area. The derricks are kept at required positions by using the guy and tackles. One boom is positioned over the hatch and other boom is position over the ship s side. The singled length of wires called preventer guys that lead from the out board side of the boom to the deck. Which have the function of taking the guy weight, are fitted When the booms are set up in the position the preventer guys (standing guys) are set up tight A three way swivel, known as a union hook, join a cargo wire or runner from each boom During the un loading process the boom centered over the hold lift the load by its runner Once the load has been lifted to sufficient height clear of any obstruction from the deck, the cargo runner from the other derrick is used to move the load over the ships side to the quay. 13

14 (c)- maximum angle of derrick to the horizontal no less than 15dig maximum angle between cargo runners not less than 120dig the out reach beyond the mid ship breath should not be less than 4m The tension should be taken off the slewing guys when the rig is set up and the tension should be on the preventer guys. If the derricks are not mark with the SWL for union purchases they should not be used for loads in excess of one third of the SWL of the derrick. Ensure to consult load diagram for union purchases The maximum SWL of the rig should not exceed the SWL of the cargo runner Do not allow stevedores to unduly long slings The preventer guy should not secure for the same eye plate on the spider band to which the slewing guy is secured The preventer guy of the boom over the side should not be rigged too far away o too close to the derrick. Use the union hook to the cargo runner to prevent twisting on the runners 14

15 Runners should not be allowed to rub against hatch coming or other structural members A competent person should be supervise the rigging of derrick The persons involved in the operation should wear protective equipments (d)-advantages and disadvantages of union purchase Advantages Fasted method for discharging break Bulk cargo and general cargo Disadvantages Can only be used for light weights The winch man highly skilled The derrick cannot be used for spot loading Re-position and rigging is time consuming Some time need two winch operators Too many wires and ropes on deck Q-19, (a)-sketch and label a Stuelcken derrick use for a heavy lift handling on cargo vessels (b)-describe the common features of a Stuelcken derrick (c)-what are the advantages having Stuelcken derrick on board (d)-stuelcken derrick can be use on the adjacent hatches for cargo handling. Describe step by step rigging procedure for working on adjacent hatches. (a) See attaché sketch (b) The ability of swing through the vertical The twin V masts give a large distances between the bases of the topping lift span The twin span system Consist of a portable remote control device All blocks swivels and goosenecks are equipped with anti-friction bearing and sealed To reduce top weight low alloy high strength steels are used 15

16 (c)- (d) 1. The working area is doubled as one derrick can serve the hatches forward and aft of its location 2. A large horizontal arc of operation is achieved due to the large distance between the bases of the topping lifts spans 3. Due to twin span system slewing guys do not obstruct the cargo working area 4. Due to portable control device the view of the operator is never obstruct 5. Not required to re-rig the derrick at any stage of the operation 6. As the moving parts are equipped with anti friction bearing and sealed very less maintenance required 7. The derrick can be secured in a short period 8. Capable of accurate spot loading 1. Release any weight from the derrick 2. Bring the derrick to the mid ship position 3. Bring it to vertical position as much as possible 4. Lower rams horn hook to holding basket at the bottom of the derrick 5. Disconnect union table from the lower blocks by unscrewing two nuts and bolts located at the union table 6. Now cargo falls can be connected to the rams horn hook on the adjacent Side of the hatch and can be used. 16

SOP GEN-007X Crane and Winch Operations

SOP GEN-007X Crane and Winch Operations Page 1 of 7 SOP GEN-007X 1.0 Introduction 2.0 Responsibility 3.0 References 4.0 Training and Qualifications 5.0 Operational Inspections 6.0 Maintenance and Load Tests 7.0 Cranes 8.0 Winches 9.0 Mobile