APPEA Lifitng and Rigging Guidelines

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Australian Petroleum Production & Exploration Association Limited Issued: August 1999Level 3, 24 Marcus Clarke St GPO Box 2201

CANBERRA ACT 2600 CANBERRA ACT 2601

Telephone: +61 2 6247 0960 Facsimile +61 2 6247 0548

INTERNET http://www.appea.com.au Email: [email protected] 000 292 713

ISBN 0 908277 21 0

Australian Petroleum Production &

Exploration Association Limited

GUIDELINES FOR

LIFTING EQUIPMENT

_______________________________________________





APPEA Guidelines for Lifting Equipment

____________________________________________________________________________ August 1999 Page 1

PREFACE

Lifting operations in the offshore petroleum industry represent potentially one of the highest risk

activities in the industry. Accordingly many standards and individual company guidelines exist to

ensure that lifting operations are performed safely using appropriate equipment.

As well as offshore lifting this guideline does cover some aspects of lifting operations at onshore

sites. In particular personnel competency requirements, registers of lifting equipment and operational aspects for lifting devices including mobile cranes are covered. During the preparation

of the guideline the technical working group recognised that onshore lifting practices were

generally well established and that a uniform standard already existed. This guideline is intended

only to supplement and does not seek to alter these well established onshore lifting practices.

APPEA has issued these guidelines to facilitate consistent lifting practices across the petroleum

industry, particularly for offshore operations. These guidelines establish appropriate design

requirements for “Lifting Gear” reflecting the dynamic effects of lifting operations from supply

vessels along with guidance on equipment marking, registers, inspection testing and maintenance.

They also describe the broad expectations for competencies of personnel associated with lifting

activities.The purpose of these guidelines is to provide operators, contractors and vendors working in the

offshore petroleum industry clear and consistent guidance on the expected standards to ensure safe

lifting operations, thereby minimising risks to personnel and assets.

APPEA WORKING GROUP MEMBERS

APPEA: David Ffrench (ESSO)

AOS: Captain Bill Korevaar

BHPP: Peter RogersESSO: Ray Lindner

IADC: Dan Ahern (ATWOOD OCEANICS)

SCHLUMBERGER: Roberto Nazareno

TIDEWATER: Andy Green

WOODSIDE: Mike Reklitis

NOBLES Peter Campbell

BHP LIFTING Andrew Jarvie

Technical Advisers:

ESSO: Doug WilliamsTRANSFIELD/WORLEY Peter Lardi

Disclaimer

The use of these Guidelines do not affect the responsibility of individual operating companies or,

their contractors to carry out operations safely having regard to their duty of care

responsibilities, and to observe statutory requirements. APPEA cannot accept any responsibility

for any incident or consequence thereof, whether or not in violation of any law or regulation,which arises or is alleged to have arisen from the use of these Guidelines.




Page 2 August 1999

CONTENTS

1 INTRODUCTION....................................................................................................................................................5

1.1 PURPOSE AND SCOPE .............................................................................................................................................5

1.2 LIFTING EQUIPMENT TERMINOLOGY......................................................................................................................6

1.3 R ELATIONSHIP WITH R EGULATIONS.......................................................................................................................7

1.4 MANAGEMENT SYSTEM .........................................................................................................................................7

2 COMPETENCY STANDARDS .............................................................................................................................8

2.1 MANAGEMENT R ESPONSIBILITIES..........................................................................................................................8

2.2 COMPETENCE OF CRANE AND FORKLIFT OPERATORS, R IGGERS AND DOGGERS....................................................8

2.3 MAINTAINERS OF LIFTING EQUIPMENT..................................................................................................................82.4 I NSPECTORS OF LIFTING EQUIPMENT .....................................................................................................................9

2.4.1 Visual check............................. ........................................................... ......................................................... ....9

2.4.2 Lifting Equipment Inspection Bodies............ ................................................................. ..................................9

2.5 NON DESTRUCTIVE TESTING (NDT) LABORATORIES ............................................................................................92.5.1 Proof Load Testing Laboratories ................................................ ..................................................... .............10

2.6 DESIGNERS OF LIFTING GEAR ..............................................................................................................................10

3 REGISTERS OF LIFTING EQUIPMENT.........................................................................................................11

3.1 I NTRODUCTION ....................................................................................................................................................11

3.2 LIFTING EQUIPMENT R EGISTER ............................................................................................................................11

3.3 LIFTING EQUIPMENT R EGISTER CONTENTS..........................................................................................................11

4 DESIGN OF OFFSHORE LIFTING DEVICES ................................................................................................134.1 I NTRODUCTION AND SCOPE .................................................................................................................................13

4.2 DESIGN, MANUFACTURE AND I NSTALLATION (GENERAL)...................................................................................13

4.3 CRANES ...............................................................................................................................................................13

4.3.1 Crane configuration ............................................... ........................................................ ...............................15

4.3.2 Performance criteria (Minimum Requirements)............................................... ............................................15

4.3.3 Environmental criteria ............................................................. ....................................................... ..............16

4.3.4 Utilities available ................................................................... ......................................................... ..............16

4.4 MOBILE CRANES..................................................................................................................................................17

4.5 GANTRY CRANES, LIFTING BEAMS AND LIFTING AIDS........................................................................................17

4.6 LIFTING POINTS ...................................................................................................................................................174.7 HOISTING EQUIPMENT (MANUALLY OPERATED) ....................................................... ..........................................18

4.8 MAN-R IDING EQUIPMENT....................................................................................................................................18

4.8.1 Cranes Used for Man Riding Operations.................................................. ....................................................18 4.8.2 Tugger and Man Riding Winches ........................................ .............................................. ............................19

4.9 SURVEYS AND I NSPECTION ..................................................................................................................................19

4.10 DOCUMENTATION ................................................................................................................................................20

5 DESIGN OF OFFSHORE LIFTING GEAR.......................................................................................................21

5.1 I NTRODUCTION ....................................................................................................................................................21

5.2 DESIGN APPROACH FOR E NGINEERED LIFTS ........................................................................................................21

5.3 OVER CHART LIFTS .............................................................................................................................................22

5.4 DESIGN OF R IGGING.............................................................................................................................................22

5.5 ACCESS TO CRANE HOOK FOR MARINE CREWS – FIFTH LEG ASSEMBLIES ..........................................................255.6 DIAGONALLING....................................................................................................................................................25

5.7 SPECIFIC R EQUIREMENTS FOR OFFSHORE USE.....................................................................................................26

5.7.1 Synthetic Slings (Refer AS 1353.17.2-1997, AS 4497.1&.2 -1997) ...................................... .........................26

5.7.2 Safety Shackles ................................................... .......................................................... .................................26

5.7.3 Eyebolts ..................................................... ............................................................ ........................................26

5.7.4 Chain Slings .................................................. ........................................................ ........................................26




____________________________________________________________________________ August 1999 Page 3

5.8 DESIGN OF OFFSHORE CONTAINER PADEYES & THEIR ATTACHMENT.................................................................27

5.9 DESIGN OF LIFTED EQUIPMENT (OFFSHORE CONTAINERS)..................................................................................27

5.10 SEA (ISO) CONTAINERS.......................................................................................................................................28

5.11 DESIGN OF SUB-SEA LIFTS ...................................................................................................................................295.12 MATERIALS OF CONSTRUCTION AND FABRICATION R EQUIREMENTS...................................................................30

5.13 DOCUMENTATION – NEW BUILD LIFTED EQUIPMENT..........................................................................................30

5.14 DOCUMENTATION FOR EXISTING LIFTED EQUIPMENT .........................................................................................32

5.15 I NITIAL LOAD TESTS (OFFSHORE CONTAINERS INCLUDING ISO CONTAINERS)...................................................33

5.16 NON DESTRUCTIVE TESTING (OFFSHORE CONTAINERS INCLUDING ISO CONTAINERS).......................................336 DESIGN OF TANKS FOR FLUIDS....................................................................................................................35

7 MARKING OF LIFTING EQUIPMENT ...........................................................................................................37

7.1 GENERAL .............................................................................................................................................................37

7.2 MARKING OF LIFTING DEVICES ...........................................................................................................................37

7.2.1 Fixed Location Padeyes......................................................................... ........................................................37

7.3 MARKING OF LIFTED EQUIPMENT........................................................................................................................377.4 CONTAINER AND R OOF IDENTIFICATION MARKINGS ...........................................................................................37

7.5 LIFTING FRAME AND BEAM MARKINGS ...............................................................................................................38

7.6 MARKING OF R IGGING .........................................................................................................................................38

8 PERIODIC INSPECTION, TESTING AND MAINTENANCE .......................................................................39

8.1 GENERAL .............................................................................................................................................................39

8.2 LIFTING DEVICES.................................................................................................................................................408.2.1 Inspection Before and After Proof Loading.............................. ................................................................ .....40

8.3 LIFTED EQUIPMENT .............................................................................................................................................40

8.4 R IGGING...............................................................................................................................................................428.4.1 Proof Loading of Rigging used for Offshore Lifting (Boat Lifts)...................................................................42

8.5 R EPAIRS AND MODIFICATIONS TO LIFTING EQUIPMENT ......................................................................................42

9 SAFE OPERATING PROCEDURES..................................................................................................................43

9.1 LIFTING OPERATIONS BETWEEN PLATFORMS AND VESSELS ................................................................................43

9.1.1 Planning .............................................. .................................................... ......................................................43

9.1.2 Communications............................................. .................................................... ...........................................43

9.1.3 Lift Preparation and Handling .................................................... ............................................................ ......449.2 PERSONNEL TRANSFERS ......................................................................................................................................44

9.2.1 Authority ..................................................... ............................................................ .......................................44

9.2.2 Duties........................................................ ............................................................ .........................................44

9.2.3 Suitability of the vessel .............................................................. ............................................................... .....45

9.2.4 Weather conditions ....................................................... .......................................................... .......................46

9.2.5 Communications................................................. ........................................................ ...................................46

9.2.6 Safety equipment and rescue procedures.................................................................................... ...................46

9.2.7 Training ....................................................... ........................................................... .......................................46

APPENDIX A ............................................................ ........................................................... ...........................................47

REFERENCE DOCUMENTS......................................................................................................................................47

APPENDIX B...................................................................................................................................................................51DEFINITIONS ................................................................ ............................................................ .................................51

APPENDIX C ............................................................. ........................................................... ..........................................57

OFFSHORE WIRE ROPE AND CHAIN SLINGS......................................................................................................57

APPENDIX D ............................................................. ........................................................... ..........................................65

DYNAMIC AMPLIFICATION FACTOR...................................................................................................................65

APPENDIX E...................................................................................................................................................................67

CONTAINER MARKING EXAMPLE .......................................................... ......................................................... ....67

APPENDIX F...................................................................................................................................................................73

INSPECTION & TESTING REQUIREMENTS..........................................................................................................73

APPENDIX G ............................................................ ............................................................ ..........................................77




Page 4 August 1999

GUIDE TO AUSTRALIAN AND INTERNATIONAL STANDARDS......................................................................77

APPENDIX H ............................................................ ........................................................... ...........................................83

GUIDELINES FOR THE PHASEOUT OF ISO SHIPPING CONTAINERS............................................................83

APPENDIX I....................................................................................................................................................................95

GUIDELINES FOR THE INSPECTION, TESTING AND MARKING OF OFFSHORE CONTAINERS ..............95




____________________________________________________________________________ August 1999 Page 5

1 INTRODUCTION

1.1 Purpose and Scope

To provide operators, contractors and vendors working in the offshore petroleum industry clear and

consistent guidance on the expected standards for design, manufacture, supply and use of lifting

equipment. These guidelines are intended to ensure safe lifting operations, thereby minimising risks

to personnel and assets.

These guidelines apply to “Lifting Equipment” used on and in the following offshore exploration

and production facilities and onshore loading facilities, e.g.:

• Platforms

• Floating production units

• Floating production, storage and offloading (FPSO) facilities

• Mobile offshore drilling units (MODUs)

• Supply vessels

• Construction vessels

• Diving support vessels

• Seismic vessels

• Buoys

• Onshore loading facilities and supply bases

These guidelines do not apply to:

• Pipe laying activities

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

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

swivels, etc)

• Heavy lift activities from construction barges

• Helicopter external lifting

Most of the “Lifting Equipment” used in drilling related operations are addressed in relevant API

standards or IADC guidelines.




Page 6 August 1999

1.2 Lifting Equipment Terminology

LIFTING DEVICES

LIFTING EQUIPMENT

LIFTING GEAR

RIGGING

Wire ropes

Wire rope slings

Chain SlingsFlat synthetic webbing

slings

Wire coil flat slings

Polyester round slings

Shackles

Hooks

Clamps

Rings

Swivels

Hammer locks

Sockets

LIFTED

EQUIPMENT

Cranes as per AS 1418

(Mobile crane, Tower crane,

Overhead crane, Hoist)

Chain Block

Cherry Picker

Davit

Forklift

In-situ lifting beam

Jack

Lever Hoist

Loading arm

Monorail.

Padeyes Section

Trolley

Winch

Bulk liquid tanks

Open freight containers

Closed freight containersMini containers

Pallets

Open top bins

Skips

Baskets

Gas cylinder racks

Spreader frames

Equipment skids

Long stock container

Modules

Padeyes Section

Lifting points & supporting

members of subsea manifolds,

christmas trees & subsea valves

Lifting points and supporting

members of machinery(skids, valves etc)




____________________________________________________________________________ August 1999 Page 7

1.3 Relationship with Regulations

The majority of Australian legislation covering safety critical equipment such as “Lifting

Equipment” is now objective based. This includes the Petroleum (Submerged Lands) (Management

of Safety on Offshore Facilities) Regulations 1996 and regulations issued under the various State

and Federal Safety and Occupational Health legislation. As such, these guidelines are structured in

such a way as to provide guidance to the offshore petroleum industry on “good industry practice”.These guidelines are not to be interpreted as industry “best practice” or minimum standards. The

onus of demonstrating that risks have been reduced to as low as reasonably practicable remains with

the individual operator or contractor.

Offshore petroleum exploration and development in Australia comes under the jurisdiction of the

Commonwealth and State or Territory Petroleum (Submerged Lands) Acts. Depending on the lease

location, regulations under the Act may be directly administered by the State or Territory or

administered by the State or Territory on behalf of the Commonwealth (as a Designated Authority).

For offshore operations supply vessels, work boats, offtake tankers, etc, come under the Navigation

Act and the detailed Marine Orders referenced within the Act. Similarly when MODUs, FPSO’s,

FPU’s, construction barges enter Australian waters they fall under the Navigation Act. When theyare moored at drill site they fall under the P(SL)A in addition to the Navigation Act, but

immediately on leaving the mooring they revert back to the Navigation Act. Loading and unloading

operations at offshore facilities are governed by the P(SL)A which is administered by the relevant

state or territory department. Operators attention is also drawn to the AMSA publication

“Australian Offshore Vessels – Code of Safe Working Practice”.

To demonstrate compliance with the P(SL) Management of Safety Regulations, operators must

ensure they have an effective integrated Safety Management System (SMS) in place that identifies,

assesses, eliminates and/or manages risk to as low as reasonably practicable.

1.4 Management System

It is expected that, as a minimum, organisations using these guidelines would have in place a formal

“Lifting Equipment Management System”.

This management system would as a minimum demonstrate how the organisation controls:

• Responsibilities for key personnel;

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

• Design, fabrication and supply of “Lifting Equipment”;

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

• Safe use of “Lifting Equipment”;

• Training and competencies of personnel ;

• Contractor or third party owned “Lifting Equipment”;

• Auditing of this management system.




Page 8 August 1999

2 COMPETENCY STANDARDS

2.1 Management Responsibi lit ies

It is the responsibility of management to ensure that personnel operating “Lifting Equipment” have

the required competencies and are familiar with specific “Lifting Equipment” and work practices

used at each facility. This may include the following:

• Awareness of relevant codes, standards and guidelines;

• Awareness of relevant competency standards;

• Knowledge of “Lifting Equipment” used on the facility;

• Lift planning procedures;

• Requirements for pre-use equipment checks;

• Requirements for moving loads around the facility;

• Routine inspection and maintenance requirements;

• Procedures for loading and unloading supply vessels;

• Procedures for personnel transfer operations.

2.2 Competence of Crane and Forkli ft Operators, Riggers and Doggers

Crane and fork lift operators, riggers and doggers working within Australia and/or Australian waters

are required to hold a certificate of competency issued by either a recognised State Authority or a

National Licence issued under the “National Occupational Health and Safety Certification Standard

for Users and Operators of Industrial Equipment” (Note: The referenced publication,

NOHSC:1006-1992, is available from the National Occupational Health and Safety Commission).

Such personnel shall be familiar and competent with facility specific “Lifting Equipment” and work

practices.

2.3 Maintainers of Lif ting Equipment

Management should ensure that maintenance of “Lifting Equipment” is carried out by suitably

qualified and competent personnel, who have knowledge of the following areas:

• Awareness of the relevant standards and regulations;

• Any site specific requirements and procedures;

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

• Inspection frequency requirements;

• Detailed inspections requirements for all “Lifting Equipment”;




____________________________________________________________________________ August 1999 Page 9

• Discard criteria;

• Disposal processes for failed equipment.

2.4 Inspectors of Lifting Equipment

2.4.1 Visual check

Competent persons, holding a certificate of competency relevant to the type of equipment, are to

carry out a visual check each time the equipment is used.

2.4.2 Lif ting Equipment Inspection Bodies

A “certified visual inspection” is a more detailed inspection than a visual check carried out on a

periodic frequency, the results of which are documented and recorded in the facility “Lifting

Equipment” Register. Certified visual inspection shall be conducted by either one of the following:

• Classification Societies with industry accepted inspection standards for “LiftingEquipment.” (e.g. DNV)

OR

• A “body” holding NATA Inspection accreditation for in-service inspection of “Lifting

Equipment” to these guidelines.

Inspection of “Lifting Equipment” should be carried out against clearly documented inspection

procedures, which include equipment rejection criteria, by suitably qualified and competent personnel as recognised by the above authorities. Refer to section 8 and Appendix I for further

details of the certified visual inspection.

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

2.5 Non Destruct ive Testing (NDT) Laborator ies

During initial fabrication, repairs and modifications as well as part of the periodic inspection

process, NDT inspection of “Lifting Equipment” shall be conducted by either one of the

following:

• Classification Societies with industry accepted laboratory accreditation for NDT testing of

“Lifting Equipment.” (e.g. DNV)

OR

• A “body” holding NATA laboratory accreditation for in-service inspection of Offshore

“Lifting Equipment” to these guidelines.

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




Page 10 August 1999

2.5.1 Proof Load Testing Laborator ies

Proof load testing laboratories shall hold accreditation to these guidelines for the relevant class of

proof load testing. Proof load testing of “Lifting Equipment” shall be conducted by one of the

following bodies:

• Classification Societies with industry accepted proof load standards for “LiftingEquipment.” (eg. DNV)

OR

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

All proof load testing reports should bear the endorsement stamp of the appropriate proof load

testing accrediting body.

Accreditation should be reviewed to ensure that it covers the equipment to be tested.

2.6 Designers of Lif ting Gear

Management should ensure that the designers of “Lifting Gear” are qualified engineers experienced

in offshore lifting and that the design is also verified by an independent qualified engineer (i.e. an

engineer who has had no part in the original design).

It is expected that the design or verification of “Lifting Gear” will be conducted by either:

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

OR

• A “body” holding NATA inspection accreditation for design verification of “Lifting

Gear” to these guidelines.

All design documentation should bear the endorsement stamp of the appropriate design verification

accrediting body.

Refers to Sections 5.1, 5.3, 5.7.3, 5.8, 5.9 and 5.14.




____________________________________________________________________________ August 1999 Page 11

3 REGISTERS OF LIFTING EQUIPMENT

3.1 Introduction

Each facility shall maintain a register or registers of all types of “Lifting Equipment” used on site

and owned by the operator. Likewise, contractors should maintain a register of their “Lifting

Equipment” on each facility. This is a statutory requirement for vessels operating under the

Navigation Act.

All suppliers of “Lifting Equipment” that is leased to offshore operators and/or contractors shall

also maintain a register of all such equipment.

3.2 Lif ting Equipment Register

A register, as a minimum, shall contain an inventory of all “Lifting Equipment” present on or at the

facility (this is equipment that effectively “belongs” to the facility).

The register of “Lifting Equipment” may be in an electronic format or in the form of a card or other

paper register system. Register systems should identify the location of all hard copy records of

design verifications, inspection certificates, maintenance records, test certificates, etc.

Because of differing recording requirements the register should be split into equipment types or

Classes, e.g. “Lifting Devices” (cranes, padeyes, etc), “Lifted Equipment” (containers, baskets, etc)

and Rigging (slings, shackles, etc).

3.3 Lif ting Equipment Register Contents

The register is expected to contain the following entries as applicable for each item of equipment:

• A full description of the equipment;

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

applicable;

• The unique identification or tag number for the item;

• Manufacturer’s serial numbers;

• Batch number of the item if applicable;

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

• Date of entry onto the register;

• Whether a Certificate of Conformity is required for the item;

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

• The location of the design verification certificate and documentation;




Page 12 August 1999

• Whether a certificate of inspection is required;

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

• For cranes, winches, containers, special “Lifting Equipment”, padeyes etc, the design and

fabrication codes and the location of the manufacturer data report;

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

• Re-inspection interval;

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

These entries shall be supported (as applicable) with the following traceable hard copy records as

issued by a body holding accreditation to these guidelines with NATA or a Classification Society

with industry accepted design and inspection standards for “Lifting Equipment”:

• Certificate of design verification;

• Current certificate of inspection;

• Type test certificate;

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

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

• Proof load test and NDT reports.

Where applicable, these entries shall be supported with traceable hard copy records of the

following:

• Original manufacturer’s data report;

• Original design calculations.




____________________________________________________________________________ August 1999 Page 13

4 DESIGN OF OFFSHORE LIFTING DEVICES

4.1 Introduction and Scope

This section provides guidance on “Lifting Devices”, as defined in Section 1.2, and their associated

equipment installed or erected on offshore facilities. These guidelines do not apply to cranes with a

maximum Safe Working Load over 200 tonnes.

4.2 Design, Manufacture and Installation (General)

“Lifting Devices” should be suitable for their intended purpose and should be of sound

construction, suitable material, of adequate strength and free from patent defects.

Equipment should be designed with due regard to the intended use with or near other equipment and

for safe use under known operating conditions, including any overload conditions which may be

anticipated, (i.e. proof load testing, etc.). Where relevant, the equipment should have efficient

control systems, guards, fences and shields. Particular consideration should be given to theeffectiveness of mountings on all “Lifting Devices”.

The design of “Lifting Devices” should be consistent in its approach with that used to design the

“Lifted Equipment” and Rigging, (i.e. a device designed to API codes, with rigging to DNV codes

and equipment to AS codes, may provide an inconsistent application of factors of safety and failure

load paths through the lift).

An independent competent person, as recognised by NATA, or a Classification Society, with

industry accepted design, testing and inspection standards for “Lifting Equipment”, should be

involved when any of the following actions are being considered:

• Initial design;

• Modifications to any “Lifting Equipment”;

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

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

4.3 Cranes

The detailed design of offshore cranes is beyond the scope of this document and is normally

completed by the specialist crane supplier. Common acceptable standards specified for offshorecranes are:

• API Spec 2C Specification for Offshore Cranes;

• Lloyds Code for Lifting Appliances in a Marine Environment, together with BS2573

Rules for the Design of Cranes;

• AS1418 Crane Code.

In order to minimise risk, an operational risk assessment should be conducted based on an analysis

of failure modes and their consequences. The safety of lifting operations, with regard to personnelon or near the facility, must be considered.




Page 14 August 1999

Additional requirements to be considered for the crane specification, depending on the principalguidance used may, include:

• Crane Operating Limitations;

• Controls and Instrumentation;

• Power;

• Primary Structural Components and Maintenance Access ;

• Slewing Rings;

• Kingpost Cranes;

• Operators' Compartments;

• Winding Gear;

• Rope Anchorage and Terminations;

• Wire Rope (hoisting and booming);

• Wire Rope Grips and Clamps;

• Wire Rope Examination and Discard;

• Hooks;

• Crane Hook Blocks;

• Ram Luff Cranes;

• Slew ring failure;

• Fatigue requirements;

• Documentation.

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

supplier.




____________________________________________________________________________ August 1999 Page 15

4.3.1 Crane configuration

Table 4.3.1. Crane Configuration Specification

Crane type A-frame / ram luffing / telescopic / king post

Boom type closed box / lattice boom

Boom length m

Auxiliary hoist required Yes/No

Prime mover diesel / electric motor

Preferred suppliers:

Transmission Hydraulic

Rotation continuous 360°

Machinery house Yes/No weather / sound proof enclosure

Control cabin / location Yes/No crane / remoteIf crane : left / right side(looking towards boom tip)

Floodlights (Total number, location)

Gas / smoke detector fixingarrangements required

Yes/No

Power outlet sockets type: spec:

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

Anti-condensation heaters required Yes / No / Manufacturer to propose

4.3.2 Performance cri teria (Minimum Requirements)

Table 4.3.2. Crane Performance Criteria Specification

Max. dynamic lift(at conditions given in Appendix 2section 3)

kg at m. minimumworking radius

Max. static lift kg at m. minimum

working radius

Max. auxiliary lift kg at m. minimumworking radius

Main hook speed (minimum) m/min

Auxiliary hook speed (minimum) m/min

Personnel lift required Yes/No kg

Installed platform design life Years

Total duty cycles

Surface temperature limitation °C




Page 16 August 1999

4.3.3 Environmental cri teria

Table 4.3.3. Environmental Criteria Specification

Ambient temperature max./min. °C/ °C

Design temperature max./min. °C/ °C

Humidity % relative/absolute

Atmosphere Saline /

Location

Surface wind

maximum instantaneous gust

m/s

m/s

Wave height (significant) m

Wave period seconds

Excessive temperature exposure flue gas exhaust °C

flare °C

boom °C

upper structure °CSnow and ice conditions Yes/No

Operating – thickness mm

Stowed – thickness mm

Hazardous area classification boom: cab:

As per IP Model Code of Safe

Practice, Part 15

power unit: crane:

Diesel exhaust emission control

standard

4.3.4 Utili ties available

Table 4.3.4. Utilities Specification

Diesel fuel Yes/No Grade:

Electricity AC (power) V φ Hz

AC (control) V φ Hz

DC V A

Emergency / uninterrupted Yes/No AC/DC

V φ Hz

Air supply (instrument quality) bar (ga) m

3/minAir supply (plant quality) bar (ga) m3/min

Potable water (limited to top-up use

only)

Yes/No




____________________________________________________________________________ August 1999 Page 17

4.4 Mobi le Cranes

Mobile cranes offshore should be classed as temporary mobile equipment and should only be used

for the purpose agreed by the operating company, the owner and a competent person.

Where mobile cranes are used for operations subject to sea-state induced dynamics, they should

generally comply with the recommendations of Section 3 and the following items should also be

considered:

• Permissible locations (i.e. area of safe operation) including adequacy of supporting

structure;

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

overboard;

• Safe limits of operation on floating installations and any associated means of stowing or

securing the crane in adverse weather conditions;

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

• Dynamic effects and de-rating for sea state operations;

• Inspection of safety-critical structural and mechanical components.

• Details should be included in an appropriate manual addressing the use of the mobilecrane in offshore operations.

4.5 Gantry Cranes, Lif ting Beams and Lif ting Aids

Gantry cranes, lifting beams, lifting frames, spreaders, etc. should be designed, constructed and

tested in accordance with a recognised standard, supplemented with any specific conditions of use

(such as operational sea-state and/or maximum list/trim and roll/pitch). Any such conditions of use

should be made clearly visible to the operator of the crane and also be stated in an appropriate

manual for the equipment.

Gantry cranes should be fitted with end limit switches and mechanical stops for all travel motions.

If travel speeds are sufficiently low to warrant over-travel being arrested by mechanical end stops

only, then approval for this mode of operation should be obtained from a competent person.

4.6 Lifting Points

Permanently attached lifting points should be designed to a recognised standard (Appendix G) and

be subject to examination and testing in accordance with these guidelines.

The design of lifting points such as padeyes, pad-ears, lifting lugs, etc. should incorporate the

magnitude, direction and effects of load distribution.

The design of the surrounding structure to which lifting points are affixed should allow

transmission of the load from the lifting point to the surrounding structure.

Adequate clearances should be provided between the lifting point and the connecting device. Lifting

points should be free from any detrimental defects caused by oxy-cutting, arc welding, etc.




Page 18 August 1999

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

comply with the current requirements.

4.7 Hoisting Equipment (Manually Operated)

Manually operated hoisting equipment should be designed, manufactured, tested and marked in

accordance with recognised codes and standards (Appendix G).

Pawls for the ratchet mechanism should either be spring-loaded or engagement with the ratchet

ensured by other positive means. Engagement should not depend solely on gravity or a tension

spring alone.

Hand chains should be smooth and free from rough areas. The effort required to operate manual

hoisting equipment should not exceed that which one person can comfortably exert from a standing

position.

If manually operated hoisting equipment is to be continually used in an area where a flammable gas

could be present, the equipment should be made spark proof and be so stated on the identification

plate.Under no circumstances should powered means be used to raise loads with a manually operated

hoist. A restriction to this effect should be displayed on the hoist or, if this is not practicable, a

suitable notice should be contained in the operation/instruction manual for the equipment.

4.8 Man-Riding Equipment

4.8.1 Cranes Used for Man Riding Operations

The following guidance applies to cranes used for personnel lifting. Outline guidance on proceduresfor transfer of personnel by basket is provided in Section 9.2.

Free fall operations of the hoist or boom motion are not permitted. Winding gear should be

equipped with a brake, mechanically operable under all load conditions. The design braking force

should be at least 120% of the braking force required to support the stipulated test overload.

Dynamic braking effects due to hydraulic transmission systems should not be considered as a

mechanical brake when using cranes for man-riding operations.

The brake should be automatically applied when the drive is in the "off" or the "neutral" position.

Any change-speed gearbox should be of constant mesh type whereby it should not be possible to

change the gear ratio while there is any load on the winch. Clutches or other means of disengaging

the drive train are prohibited for this type of operation. Brake action should be progressive in order to avoid sudden dynamic shock.

The brake should be applied automatically upon failure of the power supply to the motor and/or

control device.

A secondary brake should be fitted and be operable by the driver in an emergency situation

involving man-riding operations and arrest all crane motions. The secondary brake should be

applied directly at the drum and not through gear boxes, gear trains etc. The brake need only be of a

size sufficient for arresting the loading of persons and the basket, together with some dynamic

allowance.

An emergency stop should be fitted that can be operated by the driver in an emergency situation.

Operation of the emergency stop should arrest all crane motions by the actuation of the motion brakes. In the event of failure of the prime mover to re-start, it should be possible to recover the

load by manual means.




____________________________________________________________________________ August 1999 Page 19

Cranes which are suitable for man-riding duties should be clearly marked "SUITABLE FOR MAN-

RIDING DUTIES" at the crane operator's control location.

4.8.2 Tugger and Man Riding Winches

All tugger and man riding winches should be designed:

• with a winch operating lever which should automatically return to neutral on release inany operating position;

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

• without a clutch capable of disengaging the drive.

Winches to be used for man-riding duties should additionally be designed:

• with a secondary brake to prevent the load from falling in the event of failure of the

automatic brake;

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

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

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

• with a brake holding which is less than the minimum breaking load of the rope and more

than the maximum line pull of the winch in the man-riding mode of operation; if a high

load is applied to the winch, the brake must render before the breaking load of the rope isreached:

• with a suitable guard over the drum to provide protection to the operator in the event of

rope breakage. Such a guard should not inhibit the ability of the operator to see the

spooling action of the rope on the drum.

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

4.9 Surveys and Inspection

In determining the scope and extent of surveys, due account should be taken of applicable

legislative requirements and the various recommendations on examinations or tests given in this

section, together with the results of any such examinations or tests previously carried out.

For cranes, at least one full load test should be witnessed by a competent person.

Where examinations or tests are proposed for the purpose of or consideration with regard to crane

certification, the competent person should be consulted in advance with a view to agreeing the basis

for their acceptance and that the results of the examinations or tests are recorded and reported in a

manner that meets this purpose.

Surveys may need to be brought forward if the competent person is of the opinion that a crane has

experienced excessive loading or overloading.




Page 20 August 1999

4.10 Documentation

An appropriate operations manual should contain particulars of the relevant “Lifting Devices”. As a

minimum, the contents should include general arrangements for the machinery and equipment,

wiring and piping diagrams where appropriate, and instructions for the operation of the devices. The

manual should contain operating limits, checks and test procedures, which are required to be carried out to ensure safe operation of the equipment.

Any special instruction for safe operation of appliances, such as those for man-riding winches in

section 4.8, should be noted.

All “Lifting Devices” should have an appropriate maintenance manual which gives details of

servicing, repair, essential spares holdings and any special tools required for maintenance purposes.

All “Lifting Devices” should be provided with a test certificate containing the following

information:

• Type description;

• Model description;

• Serial number;

• Description;

• Classification of mechanism (where powered);

• Rated capacity of hoisting or hauling;

• Test load applied;

• Name and address of manufacturer;

• Name and status of signatory;

• Date of issue of certificate.




____________________________________________________________________________ August 1999 Page 21

5 DESIGN OF OFFSHORE LIFTING GEAR

5.1 Introduction

This section of the guidelines covers the general requirements for the design of “Lifting Gear” as

distinct from “Lifting Devices” such as cranes, winches, etc. Guidelines for the design of “Lifting

Devices” for offshore use are presented in Section 4.

Rigging can be selected by equipment users from manufacturers handbooks provided the factors of

safety given in section 5.4 below are met and the load does not exceed approximately 25 tonnes (the

arbitrarily selected limit for Engineering Lifts). It is anticipated that in due course rigging suppliers

will have catalogues available of “Lifting Gear” suitable for offshore lifting.

Where offshore loads exceed 25 tonnes an engineered lift should be considered [refer to AS 1666.2

(1995), section 9c]. In these cases design of all “Lifting Gear” is expected to be performed by

qualified engineers experienced in offshore lifting.

With respect to the design of “Lifted Equipment” regardless of the lifted load, it is expected that thedesign will be performed by “qualified engineers experienced in offshore lifting”. Refer to clause

2.6 for competency requirements.

5.2 Design Approach for Engineered Lif ts

For the design of “Lifting Gear” to be used for an engineered lift the design engineer’s tasks should

include but not be limited to:

• Ensuring that design criteria are acceptable to the user of the “Lifting Equipment”;

• Addressing all relevant design conditions including transport, installation, loading &

unloading, operation, temperature and fatigue considerations.

The design should consider but not be limited to:

• Weight uncertainty;

• Weight growth potential;

• Uncertainty in COG;

• Dynamic amplification (DAF) ;

• Diagonalling effects;

• Local eccentricities arising from padeye connection details;

• Drag loads on equipment to be lifted in water;

• Load Radius Chart for the “Lifting Device” (Crane);

• Wave height and period.

For engineered lifts where the rigging for a particular load has been specifically designed the

rigging requirements shall be noted in a work order or preferably attached to the load (eg, a plate

which reads "For Rigging requirement refer to Drg. No. ... ").




Page 22 August 1999

5.3 Over Chart Lif ts

For "over chart" lifts (i.e. for lifts that exceed the load radius curves for the crane in question) a lift

analysis shall be carried out in close liaison with the “Lifting Equipment” manufacturer, the

installation contractor and the operator. The Dynamic Amplification Factor (DAF) may be reduced

by limiting the sea state in which the lift can be carried out. In the case of deck or onshore lifts the

hoisting speed can be reduced to limit the dynamic effects.

These limitations shall be clearly shown on the design drawings, which are to be duly signed "Accepted for Lift" by the engineer accepting overall responsibility.

For offshore lifts, codes such as "DNV Marine Operations Part 2 Chapter 5" and "Lloyd’s Code for

Lifting Appliances in a Marine Environment" offer guidance.

5.4 Design of Rigging

These guidelines vary the required factors of safety for rigging depending on whether the rigging is

to be used offshore or onshore. The dynamic factors of safety are based on findings of the field

study “Investigation of Dynamic Amplification Effects During Offshore Lifting” Reference 65.

Non-dynamic factors of safety are addressed in a discussion paper on “Factors of Safety for LiftingSlings used in Offshore Supply Boat Operations” Reference 64.

The following equation is based on a similar equation given in AS 1666.2 (1995) section 9 and

includes a material factor (R m) such that it can be used universally.

The SWL of a sling assembly shall be calculated from the equation:

SWL = (R c R m R t R o) x P Equation 1.

4 x 9.81

Where

SWL = Safe Working Load of the sling assembly (in tonnes)

P = Minimum Breaking Force for the individual rope (kN),chain or webbing which comprises the assembly

R c = Factor for Sling Assembly Configuration (refer Table 1 AS1666.2 (1995))

R m = Material Factor (refer Table 5.4.1 )

R t = Termination Factor (refer Table 5.4.2 )

R o = Operational Factor (refer Table 5.4.3 )

Table 5.4.1 Material Factor (Rm)Sling Type Rm

Chain and Lifting Components (Ref AS3776) 1.0

Wire Rope 1.0

Flat Synthetic Webbing Slings .57

Round Synthetic Slings .57

Shackles (Grades S&T Only) 0.80




____________________________________________________________________________ August 1999 Page 23

Table 5.4.2 Termination Factor (Rt)

Sling Type Rt

Chain and Lifting Components (Ref AS3776) 1.0

Wire Rope 1.0 - 0.8

(refer Table 2 AS 1666.2 1995)

Flat Webbing .875

Round Slings 1.0

Shackles 1.0

Table 5.4.3 Operational Factor (Ro)

Type of Operation (Ro) Application

Onshore or Platform Lift 1.0 -

Offshore Lift (Hs max 3.0m)

SWL ≤ 6 tonnes

6 tonnes < SWL ≤ 10 tonnes

10 tonnes < SWL ≤ 25 tonnes

0.69

0.69-0.81

0.81-0.92

6 tonnes

SWL tonnes

SWL tonnes

Personnel Lift 0.40 -

Note: 1. For SWL > 6 tonnes, Ro may be obtained by linear interpolation between

the parameters specified.

2. Where the lift weight is not measured, the uncertainty of the lift weight shall be

considered.3. Where the Factor of Safety for wire ropes, predicted herein, is less than the

Factor of Safety as specified in AS1666(1976) the greater value shall be applied.

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

SWL = P

FoS R cWhere

FoS = 4/(R m R t R o) Equation. 2

Where the Factor of Safety as specified in Equation 2 is less than the Factor of Safety as specified

in AS1666(1976) for wire rope, the greater value shall be applied. Equation 2 is consistant with the

explicit application of termination efficiency where AS1666(1976) is based on the poorest

performing termination. Although equation 2 would allow a minimum Factor of Safety for a

conventional ferrule secured wire rope sling of 4.21 this guideline is adopting a minimum Factor of

Safety of 5 as recommended in AS1666(1976). It should be noted that the for a similar sling the

Factor of Safety as specified in AS1666(1995) would be 5.26 for which the increase in

conservatism from AS1666(1976) does not appear to have any justifiable technical basis. For

further discussion on this issue refer to Reference 64. The Factor of Safety for chains and wire rope

are provided as a function of SWL in Figure 1 and Figure 2 respectively.

Table 5.4.4 lists recommended Factors of Safety for commonly used slings in offshore and onshore

operations for direct loaded lifting arrangements. Values for other types of operations may be

determined by substituting the appropriate values of R m, R t and R o in Equation 2.




Page 24 August 1999

Table 5.4.4 Recommended Factors of Safety for Commonly Used Slings

Type of

OperationRo

Chain Sling

Rt= 1.0

Rm = 1.0

Wire Rope

Rt=0.95,

Rm =1.00

Flat Webbing

Rt=.875

Rm=.57

Round Webbing

Rt=1.0

Rm=.57

Onshore or

Platform lift1.00 4

5,

(Theoretical

value = 4.21)

8 7

Offshore Boat Lift(Hs=3.0m Max)

SWL <= 6

SWL = 10

SWL =25

0.69

0.81

0.92

5.8

5.0

4.4

6.1

5.2

5.0*

11.6

9.9

8.7

10.2

8.7

7.7

Note: 1. SWL in tonnes

2. Where the lift weight is not measured, the uncertainty of the lift weight shall be considered.

3. Where the Factor of Safety for wire ropes, predicted herein, is less than the Factor of Safety as

specified in AS1666(1976) the greater value shall be applied. *

Figure 1. Effective FOS for Chain Sling for “Offshore Boat Lifts”

Effective FoS - Chain

(Hs < 3.0m, Rt = 1, Rm = 1)

0

1

2

3

4

5

6

7

0 5 10 15 20 25

Safe Working Load (tonnes)

F a c t o r o f S a f e t y

APPEA (OFFSHORE)

AS3776 (ONSHORE)




____________________________________________________________________________ August 1999 Page 25

Figure 2. Effective FOS for Wire Rope Sling for “Offshore Boat Lifts”

(Ferrule Secured Terminations)

5.5 Access to Crane Hook for Marine crews – Fifth Leg Assemblies

Rigging assemblies should be of sufficient length to allow a rigger at ground or deck level to

connect the rigging assembly to the crane hook from the outside of the “Lifted Equipment”. During

lifting, the recommended included angle between the sling and the horizontal at padeye level is 60

degrees. Rigging assemblies with angles less than 45 degrees must be approved by the operator

prior to use. In some instances, consideration should be given to attaching a fifth leg to the top of

the assembly to ensure the top end of the rigging assembly can reach to within one metre of the

deck. Whilst the inclusion of a 5th leg will greatly assist supply vessel deck crews, it does delete the

inherent redundancy in a 4 leg assembly. For this reason a 4 leg assembly is preferred.

5.6 Diagonalling

For loads up to approximately 25 tonnes using 2, 3 and 4 point lifts, the total load should be taken

by 2 slings as required by AS 1666. Diagonalling effects should be considered for both “Lifted

Equipment” (including padeyes) and the rigging. (Not applicable to engineered lifts)

Effective FoS - Wire Rope

(Hs < 3.0m, Rt = 0.95, Rm =1)

0

1

2

3

4

5

6

7

0 5 10 15 20 25

Safe Working Load (tonnes)

F a c t o r o f S a f e t y

APPEA (OFFSHORE)

AS1666-1976 (ONSHORE)




Page 26 August 1999

5.7 Specific Requirements for Offshore Use

5.7.1 Synthetic Slings (Refer AS 1353.17.2-1997, AS 4497.1&.2 -1997)

It is recognised that there may be a need to use synthetic webbing slings and round slings for

offshore lifting of critical components. Synthetic slings should only be used where hard slings

would cause damage to the lifted load.

Factors of safety for both types of slings are given in Section 5. 4. Synthetic slings aremanufactured from nylon, polyester, polypropylene and Aramid Polyamide and their labels are

coloured green, blue, brown and yellow respectively. Only polyester (blue label slings are

considered suitable for offshore service.

Synthetic slings are more susceptible to damage than other types of slings and special procedures

should be developed for storage, inspection, identification, tagging and discard criteria.

Load testing requirements are covered in the above mentioned codes. It is generally accepted that

it is more economical to replace used slings than retest them, particularly in the smaller sizes.

5.7.2 Safety Shackles

It is preferred to use safety shackles rather than screw pin shackles. Where screw pin shackles are

used, the pins must be suitably seized using seizing wire. Plastic cable ties shall not be used to

secure pins. Shackles can be supplied as Grade S or Grade T. Generally Grade S shackles are

preferred.

5.7.3 Eyebolts

Eyebolts shall not be used for boat to facility or boat to boat lifts.

Prior to lifting using an eyebolt, the design of the eyebolt should be checked by a qualified

engineer. Refer to Clause 2.6 for competency requirements. All eyebolt lifts should be considered

as engineered lifts requiring approval.

An approved body should perform a thorough inspection of the eyebolts prior to lifts. Removal of

eyebolts for inspection should be considered. Refer to Clause 2.4 for competency requirement.

Eyebolts need not be included in registers except where the equipment is lifted on a regular basis.

5.7.4 Chain Slings

Chain slings manufactured from grade T chain (Australian Standard AS2321) have been

traditionally the preferred chain slings for offshore use. As a result of documented failures during

offshore lifts with chain slings manufactured using grade T chain, chain slings should comply with

the following guidelines.

• All new purchase of chain slings for offshore use shall specify chain slings to ISO 3076ISO 4778 or ISO 7593 until such time as Australian Standards are upgraded;

• Existing AS3775 slings using AS2321 grade T chain may still be used for lifts where there

is redundancy in the rigging arrangement (4 leg assemblies). They shall not be used for

single or two leg sling lifts where there is no redundancy.

Where chain slings are used for Offshore Lifting Operations a minimum chain size of 10mm shall

be adopted.




____________________________________________________________________________ August 1999 Page 27

5.8 Design of Offshore Container Padeyes & Their Attachment

Padeyes for “Lifted Equipment” up to a maximum weight of approximately 25 tonnes that are

intended for repeated use should be designed on the following basis:

• The dynamic amplification factor (DAF) is to be taken from the graph in Appendix D

based on the total lifted load.

• The “Design Load” shall be taken as the “Resulting Sling Force” (RSF) times the

appropriate DAF. The resulting sling load will take into account of the sling angle (apexangle of 60 degrees is common) and the diagonalling effects described in Clause 5.6.

• The load factor described in Clause 2.2 of AS1170/1 SAA loading code shall be taken as

1.0 on the basis that the maximum static load is known accurately.

• Padeye local capacity checks should be conducted using AS4100 “Steel Structures Code,”

Clause 7.5.

• A lateral load of 5% times RSF shall be applied concurrently with the RSF. The lateral

load shall be multiplied by the DAF. The lateral load shall be applied perpendicular to the

plane of the padeye at the height of the shackle pin centreline.

• The combined actions of the biaxial bending and tension should be checked using AS4100

“Steel Structures Code,” Clause 8.3.4.

The steel grade used for padeyes shall be clearly specified on the design drawings. It is recognised

that 350 grade is widely used but where padeyes are being checked on an existing container the

designer shall assume that grade 250 steel has been used unless justification for a higher grade

exists.

Hole sizes in padeyes should be equal to the shackle pin diameter plus 3mm or 4% greater than the

shackle pin diameter, whichever gives the larger hole. The thickness of the padeye should be at least

75% of the shackle width to avoid “twisting” the shackle. The maximum thickness of the padeye

shall be such that a total minimum gap of 5mm is maintained to avoid “binding”

5.9 Design of Lif ted Equipment (Offshore Containers)

“Lifted Equipment” consisting of structural steelwork such as: offshore containers skids, skips,

frames and bins which are intended for repeated use shall be designed in accordance with DNV 2.7-1.

The container shall be checked for two conditions as follows:

• 4 point in accordance with Clause 3.2.1.1 of DNV 2.7-1.

• 2 point lift in accordance with Clause 3.7.1.3 of DNV 2.7-1.

The allowable stress for both conditions is given in clause 3.2 of DNV 2.7-1. Structural designer’s

attention is also drawn to clause 3.2.3 of the DNV certification notes 2.7.1 regarding minimummaterial thickness.




Page 28 August 1999

Where a material other than structural steel is used, a design engineer should determine the

appropriate design standards and load factors.

5.10 Sea (ISO) Containers

Sea (ISO) Containers can be described as containers built for international shipping and are

designed to carry general purpose cargo internationally and interstate. They generally have “twistlock” type corner fittings for lifting with a purpose built frame. Sea (ISO) containers are not

specifically designed for use as offshore containers in operations associated with the offshore

petroleum industry.

Such containers intended to be used offshore should be load tested to the requirements of IMO

circular MSC 860.

It is recommended that the use of such containers be phased out as soon as possible. A target date of

December 31st 2000 has been set for the complete phase out of ISO containers. Contractors are

advised to check with individual operators for their requirements with respect to the phase out of

ISO shipping containers. During the transition period, the following guidelines should apply to their

use as offshore containers:

• They should not be loaded above 40% of their ISO MGW rating and load tested in

accordance with Section 7;

• All lifting should be conducted using padeyes. Twist lock fittings shall not be used for

lifting;

• There should be trace-ability of the material used for padeyes fitted to the container and of

all welding carried out on the container;

• Closed and open top ISO containers greater than 20 feet (6.4 metres) in length should not be used offshore. Open top ISO containers should not be used as offshore containers;

• Prior to any intended offshore use, thorough inspections should be carried out on the

container’s floor support members and door latching mechanisms. These are critical to the

container’s integrity;

• Inspections should be conducted by competent persons. Refer to clause 2.4.2 for

competency requirements;

• Forklift pockets shall only be used for onshore lifting;

Prior to the container phase out date, inspection and testing of ISO shipping containers used in the

offshore oil and gas industry should be performed according to the APPEA ‘Guidelines for the

Phase Out of ISO Shipping Containers’ (Refer Appendix H).




____________________________________________________________________________ August 1999 Page 29

5.11 Design of Sub-sea Lif ts

Sub-sea lifts are a specialised form of lift the design of which should only be undertaken by

qualified engineers with experience in this area. Generally, the design of “Lifting Equipment”

should follow the same approach as that for a similar lift in air. Sub-sea “Lifting Equipment” should

be designed in accordance with “DNV Marine Operations, Part 2 Chapter 6 - Sub-Sea Operations”

or a recognised equivalent. The lift design should take into account factors specific to the offshore

environment in which the lift is being conducted. As a minimum, consideration should be given tothe following factors associated with subsea lifts, many of which are highly dependent on the shape

of the equipment being lifted.

• Viscous drag due to diversion of water around the “Lifted Equipment” (noting that velocityof equipment in water = winch velocity plus angular velocity due to vessel roll);

• Apparent additional inertia due to the “Lifted Equipment” accelerating the surroundingfluid. (commonly referred to as the added mass);

• Reduced mass of the “Lifted Equipment” in water due to buoyancy;

• Near surface and near seabed stability due to the vibration absorption/amplification of thesurrounding fluid.

• When the “Lifted Equipment” is at or just above the air/water interface, allowing for themass of the water to be temporarily supported when waves break over the equipment;

• Increased mass due to marine growth and entrapped sediments when retrieving “Lifted

Equipment”;

• Suction when lifting off the sea bed;

• When in water, force due to the apparent additional inertia from accelerated water = mass of water x g x (DAF - 1.0)

• Force due to equipment, marine growth and sediments= mass of items in water x g x DAF).

As the hook of the “Lifting Device” will rise and fall in the water due to vessel roll, rigging for

“Lifted Equipment” needs to be of sufficient length to avoid the hook striking divers, ROV”s and

other sub-sea equipment in the vicinity of the lift. Padeyes and rigging should be of a suitable

colour and of sufficient size to enable easy location and use by divers or ROV’s.

Many of the above factors can be reduced by the use of specialised equipment and techniques.

When a self-compensating winch or other line load control system is used, the effects of vessel roll

on dynamics and velocity in water may be reduced. When an item is lifted off the sea bed, suction

effects can be reduced by sliding before raising. Excessive mass due to marine growth and

entrapped sediments may be removed prior to lifting.

The above factors cannot be avoided by assuming motion of the “Lifted Equipment” is always

downward, as any requirement to stop lowering prior to placement, either planned or in emergency,

may result in their occurrence.




Page 30 August 1999

5.12 Materials of Construction and Fabrication Requirements

Fabrication of “Lifting Equipment” shall be in accordance with recognised international or

Australian standards.

All materials should be suitable and safe for their intended purpose; for the fabrication, transport,

installation and use of “Lifting Equipment”; and to comply with the requirements for materials in

nominated Australian or international standards. Particular attention should be paid to the fracture

toughness of materials.

Vendors and fabricators should have quality management systems equivalent to ISO9001, ISO9002

or ISO9003. All materials used in the fabrication of “Lifting Equipment” shall have documentation

in accordance with the contractor’s quality control procedures to demonstrate trace-ability. As

applicable, some or all of this documentation may be required to support the equipment register.

5.13 Documentation – New Build Lifted Equipment

All “Lifted Equipment” should be issued with a Certificate of Conformity prior to their initial proof

load testing. This must be issued by one of the following bodies, either as a separate document or asa dedicated section included on the Load Test Certificate and must be signed by an endorsed

signatory of either of the following:

• Classification societies with accepted design standards for offshore “Lifted Gear” (e.g.DNV);

• A “body” holding NATA accreditation for design verification of Offshore “Lifted Gear” to

these guidelines;

The Certificate of Conformity should contain the following information:

• Assurance that the lifted item (container) has been designed, fabricated and tested tooffshore “Lifting Equipment standards (e.g. DNV or other). The owner of the equipment

shall retain the certificate;

• Containers that are required to comply with the International Maritime Dangerous Goods

(IMDG) regulations, should also be certified in accordance with the IMDG code.

The certificate of conformity shall be based on the following documentation collated in an “as

built” dossier, which shall be retained by the owner:




____________________________________________________________________________ August 1999 Page 31

• Structural calculations;

• Drawings;

• Specifications for welding procedures;

• Welder qualifications;

• Material certificates;

• Report on trace-ability of materials;

• Report from fabrication inspection;

• Report from non-destructive examination;

• Report from prototype testing;

• Report from proof testing;

• Report from final inspection;

The certificate of Conformity shall contain the following information:

• Container fabrication number;

• The Certificate number;

• Description of the container including;

• External dimensions;

• Number of lifting points;

• Name of fabricator;

• Date of fabrication;

• Maximum gross weight in kilograms;

• Tare weight in kilograms;

• Net weight in kilograms;

• Reference to the “as built” dossier;

• The total gross weight in kilograms applicable to the all points lifting test and the actual

method of test;

• Specification of lifting set;

• Angle of legs (from horizontal);




Page 32 August 1999

• Shackle bolt diameter;

• Required safety factor (against breaking);

• Conformity to other requirements and codes;

• A statement that the container has been designed, fabricated and tested in accordance with

this guideline;

• Remarks;

• Signature on behalf of the certifying body.

Proprietary devices and “Lifted Equipment”, such as drum lifters, plate clamps, etc, should be

accompanied by schematic drawings and a maintenance and operating manual and should only be

used for onshore and on platform lifts.

“Lifted Equipment” may be type or batch tested where required by Australian or international

standards. Evidence of type testing status (in the form of third party certification) shall always be

sought for new equipment. Examples of “Lifting Equipment” requiring type testing to destruction to

Australian Standard are as follows:

• Serial hoists and winches AS 1418.2

• Flat synthetic webbing slings AS 1353

• Eyebolts AS 2317

• Synthetic round slings AS 4497 parts 1 & 2

5.14 Documentation for Existing Lif ted Equipment

It is recommended that a certificate of conformity be issued for existing “Lifted Equipment” by

December 31, 2000 or the next due date for periodic load testing which ever is the sooner. The

minimum requirement to enable a certificate of conformity to be issued for existing “Lifted

Equipment” are as follows:

• Existing “Lifted Equipment” is inspected in accordance with Section 8 and Appendix I

and found to have passed the certified visual inspection and NDT where appropriate (eg.

padeyes).

• Padeye designs should be reviewed by an experienced Engineer 1 to ensure compliancewith clause 5.8. Where padeyes do not meet this standard they should be modified

appropriately.

• The design of the container has been reviewed by an experienced Engineer 2. The review

should confirm that the item of “Lifted Equipment” has sufficient structural integrity to

pass load tests specified in Table E.2.

1 Refer to Clause 2.6 for competency requirements

2 Refer to Clause 2.6 for competency requirements




____________________________________________________________________________ August 1999 Page 33

• Load testing of “Lifted Equipment” is conducted by an appropriate body in accordance

with Table E.2.

• Load testing of rigging is conducted by an appropriate body in accordance with Table

E.3.

• Rigging shall meet the requirements of Appendix C, where existing rigging is retained

some reduction in the maximum SWL will be required.

5.15 Initial Load Tests (Offshore Containers including ISO Containers)

When new containers are built or containers being put back into service after a major repair or

modification or are being put into offshore service for the first time, they shall be load tested by an

appropriate body. The accrediting body may request a drop test of containers when verifying adesign for the first time. Refer to Clause 2.5.1 for competency requirements.

The following points should be observed:

• In the case of Sea (ISO) Containers the internal test load is to be based on the maximum

gross mass (MGM) determined in accordance with Section 5.10. For purpose built

containers, the MGM identified on the container’s identification plate should be used.

e.g.

MGM = 9.6 Tonnes,

Tare = 2.5 TonnesTest load For 4 point lift = (2.5 x 9.6) - 2.5 = 21.5 Tonnes

(to be placed in the container)

• Precautions should be taken when securing test loads, particularly for a 2 point lifting test.

Where a large number of identical containers are manufactured, guidance on the number to be

tested is given in DNV Certification Notes 2.7-1 Section 4.

The container shall be considered to have passed the initial load test provided there is no permanent

deformation of the container. Deformation can readily be measured using two taut wires strung

between the diagonal corners of the container.Where proof loading is not a viable option, (i.e. where access for loading is restricted such as for

transportable buildings with small doorways) structural assessment of the container may be

determined by a certified visual inspection. The certified visual inspection of the container shall be

conducted by an appropriate body. Refer to Clause 2.4.2 for competency requirements.

5.16 Non Destructive Testing (Offshore Containers including ISO Containers)

NDT at fabrication shall include inspection of the lifting points (padeyes) and the connections

immediately adjacent to the lifting points as a minimum.Consideration should also be given to the NDT inspection of all primary members and their

connections.




Page 34 August 1999

NDT inspection shall be conducted by an appropriate body. Refer to Clause 2.5 for competency

requirements.




____________________________________________________________________________ August 1999 Page 35

6 DESIGN OF TANKS FOR FLUIDS

Tank design shall conform to relevant sections of:

• AS 1692 ‘Tanks for Flammable and Combustible Liquids’

• AS/NZ 3711.6 ‘Tank Containers’

• IMDG Code

• DNV 2.7-1 ‘Offshore Containers’

• ISO 1496-3 ‘Freight Containers – Specification and Testing’

• prEN 12079 ‘Offshore Containers – Design, Construction, Testing, Inspection

and Marking’

The APPEA guidelines for offshore tanks for fluids coincide with the requirements of DNV 2.7-1,

section 3.5 and prEN12079, section 5.5.3.

The following is an extract from prEN12079:

“Tanks for dangerous cargoes shall fulfil the requirements of the IMDG Code and shall be

designed according to recognised rules for pressure vessels. A tank and its support shall be

able to withstand lifting and impact loads. In addition, due account shall be taken of fluid

surge arising from partly filled tanks.”

Note: Chapter 13 of the general introduction to the IMDG Code does not allow tanks with a lengthabove 3m to be handled by forklift in a loaded condition. Special protection of the tank and fittings

in the area near the fork pockets is required.

On tank containers for dangerous cargoes, all parts of the tank and fittings shall be suitably

protected from impact damage by a frame, suitable for offshore service where applicable. In

addition to the IMDG Code, the following shall apply:

• Beams, plates or grating, shall protect the top of the tank and its fittings. No part of the

tank or its fittings shall extend above a level 100mm below the top of the framework. It

shall not be possible for any part of the lifting set to foul fittings, manhole cleats or other

protrusions on the tank.

• Protective beams shall be placed at or near the location where the tank shell is nearest to

the outer plane of the sides. Beams shall be spaced sufficiently close together to give the

necessary protection.

• At the maximum calculated elastic deflection of any side member, the residual clearance

between the member and any part of the tank shell or its fittings shall be at least 10mm.

• No part of the underside of the tank shell (including sumps), the bottom valves or other

fittings shall extend below a level 150mm above the bottom of the framework. Any such

part extending below a level 300mm above the bottom of the framework shall be protected by beams or plating.




Page 36 August 1999

• Tank containers designed with direct connection between the tank and the side or top frameelements shall be subject to special consideration by the operator or during operation to

avoid damage.




____________________________________________________________________________ August 1999 Page 37

7 MARKING OF LIFTING EQUIPMENT

7.1 General

All “Lifting Equipment” shall be marked with an individual identification code (“Unique Number”)

and the safe working load (SWL) as determined from the design. Where appropriate, for certain

“Lifted Equipment”, the SWL may be replaced by the tare and gross. The identification code shall

enable the operator to link the manufacturer and test certification numbers. For contractor owned

equipment, this code should include unique character(s) or colour to indicate the owner.

If the use of an item of “Lifting Equipment” is restricted to certain types of operations, this shall be

marked on the item. For example, a spreader beam which has been designed for onshore use, shall

be marked, “ONSHORE USE ONLY; NOT FOR OFFSHORE BOAT LIFTS”

7.2 Marking of Lif ting Devices

7.2.1 Fixed Location Padeyes

Valid certified padeyes which have undergone proof loading (to Marine Orders 32 requirements as

a minimum) and non destructive testing should be identifiable at point of location with the padeye

centrally positioned in a 30 cm x 30 cm black painted square (minimum size). The SWL and the

identification number should be stenciled in white within the black square.

7.3 Marking of Lif ted Equipment

“Lifted Equipment” including equipment containers, skips, baskets, frames and similar items are

expected to be marked with the information as shown on examples of marking plates provided inAppendix E or a similar alternative.

All characters marked on the container (e.g. Tare, Nett and Gross) should be durable, of

proportionate width and thickness and in a colour contrasting with that of the container. The

markings should be clearly legible and, if painted, stenciled.

Manufacturer’s plates should be of a suitable size for the required information as indicated in

Appendix E and should be of durable material (such as stainless steel) and securely fixed in a

visible but protected location.

Inspection & test plates should be of a suitable size as indicated in Appendix E, should. The plates

should be updated or replaced when either load testing, NDT or certified visual inspection is carried out.

Containers and tanks used for dangerous cargoes should be marked according to the requirements of

the IMDG Code, in addition to the marking requirements of this Section.

7.4 Container and Roof Identification Markings

Each container should be marked with a container number issued by the owner as a unique

identification, which should be the common cross-reference on all in service certification, shipping

documentation, etc.

The container number shall be prominently displayed on all sides of the container (as viewed from

ground level) in characters of contrasting colour, not less than 75 mm high.




Page 38 August 1999

If the container has a roof, the container number should be displayed on the roof, in characters not

less than 300 mm high (or less if space is limited). The marking should be carried out in such a way

as to avoid incorrect interpretation (e.g. by underlining). Where applicable, the lower edge marking

should be positioned near the side of the container in which the door is located.

7.5 Lif ting Frame and Beam MarkingsThe minimum marking required for each lifting frame and lifting beam should include ID No,

TARE and SWL. The marking should be done using 50 mm letters. Where required, the design

approval number allocated by the relevant Statutory Authority should be added. Where no suitable

location exists, painted markings down to 25 mm, on a securely fixed plate are acceptable. Stamped

markings should not be less than 8 mm in height.

7.6 Marking of Rigging

The appropriate Australian Standards provide all marking details for rigging. Wire rope riggingassemblies shall be tagged in accordance with AS1666.1 Section 7. Chain rigging assemblies shall

be tagged in accordance with AS3775 Section 8.




____________________________________________________________________________ August 1999 Page 39

8 PERIODIC INSPECTION, TESTING AND MAINTENANCE

8.1 General

The periodic inspection, testing, and maintenance (including repairs) of all “Lifting Equipment”,

including contractor owned, shall be conducted by competent, qualified personnel accredited to

these guidelines by NATA or a Classification Society with industry accepted standards in the

inspection, testing and maintenance of “Lifting Equipment”. (Refer Sections 2.4–2.6 for

competency requirements) Periodic inspection, testing and maintenance shall be conducted in a

manner to ensure safety to people and plant. When requested, contractors are expected to supply the

operator with, copies of all relevant certificates before the “Lifting Equipment” is used at any

location under the operator’s jurisdiction.

A specific inspection, maintenance and testing plan should be developed for each “Lifting Device”,

each item of “Lifted Equipment” and rigging assembly or item. Where a safety case is in place this

plan should be risk based and developed in accordance with the appropriate safety case guidelines.

The inspection, testing and maintenance plan should consider the following factors:

• Manufacturer’s recommendations;

• Statutory requirements;

• Relevant historical data;

• Frequency of use;

• Operational environmental conditions.

The plan should address:• Periodical inspection and maintenance routines (e.g. weekly, annual);

• A feedback loop to allow modifications to routines based on performance;

• Procedures for documenting results of inspections and tests;

• Procedure for colour coding inspected and tested equipment;

• Inspector’s responsibility and qualification matrix.

Records of testing, inspection, maintenance, repair and modification should be included in the

“Lifting Equipment” Register.

All “Lifting Equipment” shall be visually checked prior to each use by appropriately certified crane

driver, dogger or rigger (as applicable). This inspection should ensure that:

• Equipment is appropriate for load to be applied;

• Equipment is in good condition;

• Equipment is correctly labeled;

• Equipment for onshore use is not being used offshore.




Page 40 August 1999

Non complying equipment shall be tagged and either removed from site or repaired.

Scheduled testing and inspections should include test loading, non-destructive testing (NDT) and

visual inspection (as appropriate). Recommended inspection and testing frequencies are provided in

Appendix F.

Variations to these recommended frequencies are acceptable where a reliability based approach is in

place under a facility’s safety case.

8.2 Lif ting Devices

8.2.1 Inspection Before and After Proof Loading

For “Lifting Devices” and associated rigging, inspection should be performed in accordance with

the Australian Standards.

For equipment not covered by Australian Standards, the equipment owner in conjunction with the

inspector should select the most appropriate of those inspection requirements provided in AS 1418for “other devices”.

For specially fabricated devices such as overhead padeyes, the requirements for “Lifted Equipment”

should be applied.

8.3 Lif ted Equipment

The following requirements for inspection apply to “Lifted Equipment”. Note that these

requirements are based on DNV recommendations for periodic inspection of “Lifted Equipment”.

These requirements are guidelines for inspection or repair organisations to develop their owndetailed work instructions or procedures. These requirements should be subject to the equipment

owner and/or users approval.

All “Lifted Equipment” should be periodically inspected by an appropriate body. Refer to Clause

2.4.2 for competency requirements.

The inspection should meet the following requirements:

• Prior to testing, key dimensions and straightness should be measured;

• Structure should be visually examined for corrosion, mechanical damage and injurious

deformation;

• All accessible load bearing welds should be visually examined to ensure freedom from

defects;

• The lifting points should be visually examined for distortion, mechanical damage or any

other sign of distress or overload;

• Doors, frames, seals, hinges, locks etc. should be visually examined and functionallychecked to ensure that they operate in a satisfactory manner without undue force being

required;




____________________________________________________________________________ August 1999 Page 41

• The floor should be visually examined to check that it is substantially flat with no sign of

distress or overload. Drainage facilities, where fitted should be examined, e.g. drain holes

should be clear of debris etc.;

• The paint markings and plates should be checked to see that they meet the

recommendations of this document;

• Inspect lifting set for: rating, condition, currency of test etc.;

• If due or required proof load test. (Proof load test to be conducted prior to NDT);

• After completion of a proof test load, the equipment should be re-examined for signs of

permanent deformation caused by the test. Any deformation or weld defect caused by the

load test shall result in the withdrawal of the equipment from service until all such faults

have been corrected and a further satisfactory load test completed;

• NDT by the method nominated on the drawings if due, or required;

• Welds to all padeyes and members directly supporting padeyes should be subject to 100%

magnetic particle inspection (MPI);

• Where it is determined that a fault is related to design or fabrication quality, a

modification or repair method shall be developed, and approved by the responsible

person, before commencement of any rectification works;

APPEA detailed guidelines for the inspection, testing and marking of offshore containers are

provided in Appendix I.




Page 42 August 1999

8.4 Rigging

8.4.1 Proof Loading of Rigging used for Offshore Lifting (Boat Lifts)

The rigging for the “Lifted Equipment” shall be subject to a proof force that is not less than 50% of

the rated minimum breaking load (MBL) of the member.

Proof Load = 50% x R t x R m x MBL,

Where R t and R m are defined in section 5.4

Where all the components of the sling have been proof tested, but any component has been subject

to further processing subsequent to any further earlier proof testing, the rigging shall be subject to

further proof testing.

The sling shall withstand the application of the proof force, without sustaining damage that may

affect its intended function or safety. The sling shall also be free from any deleterious permanent set

or defects visible to the unaided eye.

Proof load testing of rigging and NDT testing as appropriate shall be conducted by an appropriate

body. Refer to Clause 2.5 and 2.5.1 for competency requirements.

8.5 Repairs and Modifications to Lifting Equipment

Repairs and modifications to “Lifting Devices” should be carried out to conform with the original

manufacturer’s specification and in accordance with Section 4. For “Lifted Equipment” where it is

not clear whether a member is structural or not, guidance should be sought from a qualified design

engineer. Design changes that alter the original structural details or safe working load capabilities of the “Lifting Equipment” should be approved by a qualified design engineer. Refer to clause 2.6 for

competency requirements.

“Lifting Equipment” shall be proof load tested following repairs involving modifications or heat

application to structural members.

All repairs or modifications should be recorded in the “Lifting Equipment” Register (Section 3).




____________________________________________________________________________ August 1999 Page 43

9 SAFE OPERATING PROCEDURES

9.1 Lif ting Operations between Platforms and Vessels

9.1.1 Planning

The Australian Offshore Support Vessel Code of Safe Working Practice provides guidance on

lifting operations between platforms and vessels.

The safe conduct of lifting operations involving the transfer of cargo between a platform and a

vessel require planning and a high level of communications among the parties involved in these

operations.

Prior to the start of any lifting operations, the communications between the person in charge of the

facility and the Master of the vessel, or their appointed deputies, should address the following

issues:

• The suitability of existing and forecast weather conditions for the required lifting

operations involving the vessel;

• Communications arrangements between the facility and the vessel during the liftingoperation;

• Any limitations or restrictions affecting, or which may interrupt, the proposed operations;

• The nature and weights of the cargo to be transferred and any special lifting requirements;

• Whether any of the proposed lifts require special consideration, safeguards or controls

during lifting, or special securing arrangements on the vessel;

• Rigging arrangements to be used and any special rigging requirements;

• Procedures to be used in the event of an emergency occurring while lifting operations are being conducted.

9.1.2 Communications

Safe lifting operations rely on there being effective communications among the Master of the

vessel, the person in charge of the facility, the crane operator, the deck officer in charge on the

vessel and the deck crews on both the facility and the vessel. A reliable radio communication link

on a dedicated channel or frequency should be maintained throughout the operations. The crane

operator on the facility should have direct radio communication with the vessel.

The crane operator should have a clear view of the deck areas on both the facility and the vessel.

Where this is impractical, a dogger should be so stationed as to have a clear view of the deck area to

assist the crane operator. Directions given to the crane operator by the deck crew on the vessel must

only be given by one person who has been clearly identified for that purpose.




Page 44 August 1999

9.1.3 Lif t Preparation and Handl ing

Wherever practicable, all lifts should be pre-slung using rigging which conforms to these

guidelines. Rigging should allow the deck crew to connect / disconnect the lift at deck level.

Open cargo baskets containing loose materials should be provided with safety nets or covers to

prevent discharge of the contents during lifting operations or while in transit. Doors and lids on

closed containers must be securely fastened.

No container should be loaded in excess of its rated capacity. Material should not be added to

containers, skips, cargo baskets, etc already transferred to the deck of a vessel unless it is safe to do

so, the capacity of the container will not be exceeded, and the change to the loading is recorded on

the manifest.

9.2 Personnel Transfers

Personnel baskets should only be used in emergency or in other circumstances where the use of

alternative means of transferring personnel is impractical or unsafe. They should only be carried out

under the authority of the person in charge of the facility and with the agreement of the personnel being transferred and the master of the vessel involved.

Each facility should have documented procedures for this type of operation. These procedures

should address the issues identified in these guidelines.

9.2.1 Authority

The person having the authority to approve personnel basket transfers should be clearly identified.

Approval should not be given unless this person is satisfied that the personnel involved agree to the

transfer operations and the transfer can be safely carried out.

9.2.2 Duties

The duties of personnel in supervising or carrying out the personnel basket transfer should be

clearly defined. Generally, this would include the person in charge of the facility, the crane

operator, the Master of the vessel, and other people nominated by the person in charge and the

Master of the vessel to undertake specific duties.

The Person in charge of the facility should:

• be aware of the reason for the transfer;

• be satisfied with the fitness and training of the people to be transferred;

• be satisfied as to the suitability of the vessel;

• know the limitations of visibility and sea state;

• be aware of the limitations on transfer by night;

• be aware of the suitability of the crane for personnel transfer;

• check the wind speed limitations on crane operations;

• establish satisfactory communications with the Master of the vessel involved in the

transfer;

• ensure that participants understand the procedures involved;




____________________________________________________________________________ August 1999 Page 45

• be satisfied with the competence and experience of the crane

driver;

• be satisfied with the inspection and testing of the personnel basket.

The Master of the vessel should confirm to the person in charge of the facility that:

• the transfer has been accepted and the procedures have been understood;

• the vessel has a satisfactory station keeping capability;

• the deck crew have been fully briefed;

• the people to be transferred have been adequately briefed and are fit to

be transferred.

The crane operator should ensure that:

• the crane is fully operational;

• the wind speed is satisfactory for safe operation;

• the requirements and procedures involved are clearly understood;

• the dogger and the transfer area are clearly visible;

• adequate communications have been established.

The dogger and deck supervisor should ensure that:

• the transfer procedure is understood;

• they are clearly identifiable as dogger and deck supervisor.

• the personnel basket is correctly used;

• the transferees are fit for transfer and understand the procedures;

• proper communications have been established;

• respectively they have a full view of the transfer areas.

Individuals who are to be transferred should:• ensure that they understand the transfer procedure;

• confirm that they are agreeable to the transfer;

• be able to use correctly the safety equipment provided;

• observe all instructions from those in charge of the operation.

9.2.3 Suitabil ity of the vessel

The type of vessel considered suitable to carry out a transfer should be determined by its ability tomaintain station alongside the facility and have sufficient clear deck space to safely receive the

basket.




Page 46 August 1999

9.2.4 Weather conditions

Weather conditions are critical factors impacting on the safety of personnel basket transfers. Factors

which should be taken into account include visibility, wind and sea state. Guidelines should be

provided which specify the maximum wind speed and sea state beyond which basket transfer is not

permissible, including the wind speed limitations for crane operations and the effect of weather

conditions on the stability of the vessel.

9.2.5 Communications

Both radio and visual communication should be established and maintained between those

personnel conducting the operation.

9.2.6 Safety equipment and rescue procedures

The procedures should specify the type of safety equipment to be worn by personnel beingtransferred and the rescue arrangements made. Personnel being transferred should wear life-jackets,

suitable clothing and other specified safety equipment. Life-jackets should be equipped with

suitable means of illumination during night transfers. The standby vessel should be in close

attendance during transfer, with the rescue boat ready for immediate launching.

9.2.7 Training

Personnel will be transferred by basket in greater safety and with less apprehension if they, and the

personnel conducting the transfer, have received training in the techniques involved. The type of

training required can be included in installation drills. Inexperienced people or those not trained inthe use of personnel baskets should always be accompanied by someone who has been trained in

personnel transfer procedures.




____________________________________________________________________________ August 1999 Page 47

APPENDIX A

REFERENCE DOCUMENTS




Page 48 August 1999

LEGISLATION

1. Petroleum (Submerged Lands) Act 1967 [PSLA]

2. Petroleum (Submerged Lands) Acts: Schedule of Special Requirements as to Offshore

Petroleum Exploration and Production

3. Navigation Act 1912 and associated Regulations and Marine OrdersMO Part 32 “Cargo Handling Equipment and Safety Measures”

MO Part 44 “Safe Containers”

4. Explosives and Dangerous Goods Act

5. Occupational Health, Safety and Welfare Act

6. WA: Occupational Safety and Health Act 1984 and Associated Regulations 1996

7. NT: Work Heath Act 1992

8. NT: Work Health - Occupational Health and Safety Regulations 1992

AUSTRALIAN AND NEW ZEALAND STANDARDS ETC.

9. AS ISO-1000 The International System of Units and its Application

10. AS 1138 Thimbles for Wire Rope

11. AS 1171 Non-Destructive Testing Magnetic Particle Testing of Ferromagnetic

Products, Components and Structures

12. AS 1163 Structural Steel Hollow Sections

13. AS 1353 Flat Synthetic Webbing Slings

14. AS 1380 Fibre Rope Slings

15. AS 1418 Cranes (Including Hoists and Winches)

16. AS 1438 Wire - Coil Flat Slings

17. AS 1504 Fibre Rope – Three Strand Hawser Laid

18. AS/NZS 1554 Structural Steel Welding

19. AS 1650 Hot-Dipped Galvanised Coatings on Ferrous Articles (superceded in part by

AS/NZS 4534 but remains current)

20. AS 1657 Fixed Platforms, Walkways, Stairways, Ladders,

21. AS 1664 Aluminium Structures

22. AS 1666 Wire Rope Slings

23. AS 2068 Flat Pallets for Materials Handling

24. AS 2076 Wire Rope Grips for Non-Lifting Applications

25. AS 2089 Sheave Blocks for Lifting Purposes

26. AS 2207 Non-Destructive Testing for Ultrasonic Testing of Fusion Welded Joint in

Carbon and Low Alloy Steel27. AS/NZS 2312 Guide to the Protection of Iron and Steel against Exterior Atmospheric

Corrosion

28. AS 2317 Collared Eyebolts

29. AS 2318 Swivels for Hoists

30. AS 2319 Rigging Screws and Turnbuckles

31. AS 2321 Short Link Chain for Lifting Purposes (Non Calibrated)

32. AS 2550(1982) Cranes - Safe Use

33. AS 2741 Shackles

34. AS 2759 Steel Wire Rope - Application Guide

35. AS 3569 Steel Wire Ropes

36. AS/NZS 3678 Structural Steel - Hot Rolled Plates, Floor Plates and Slabs37. AS/NZS 3679.1 Structural Steel - Part 1: Hot Rolled Bars and Sections

38. AS/NZS 3679.2 Structural Steel - Part 2: Welded I Sections

39. AS 3775 Chain Slings - Grade T




____________________________________________________________________________ August 1999 Page 49

40. AS 3776 Lifting Components for Grade T Chain Sling

41. AS 3777 Shank Hooks and Large Eye Hooks - Maximum 25 Tonne

42. AS 3990 Mechanical Equipment – Steelwork

43. AS 4048 Flat Pallets for Materials Handling (1100mm x 1100mm Suitable for use in

ISO Series 1 Freight Containers)

44. AS 4100 Steel Structures

45. AS 4142 Fibre Rope

46. AS 4497 Roundslings - Synthetic Fibre, Parts 1 & 247. AS B291 Lifting Rings & Links

48. AMSA Marine Orders part 44

49. AMSA Marine Orders part 32

50. AS/NZS 3711 Freight Containers

INTERNATIONAL STANDARDS

46. BS 2573 Rules for the Design of Cranes

47. BS 2903 Higher Tensile Steel Hooks for Chains/Slings Blocks and GeneralEngineering Purposes

48. BS 7072 Code of Practice for Inspection and repair of offshore containers (This

document will be replaced by EN12079)

49. DNV Marine Operations - Part 2: Operation Specific Requirements, Chapter 5:

Lifting.

50. DNV Marine Operations - Part 2: Operation Specific Requirements, Chapter 6:

Sub-sea Ops.

51. DNV Certification notes No 2.7-1. Offshore Containers

52. DNV Certification notes No 2.7-2. Offshore Service Containers

53. prEN 12079 European Committee for Standardisation. - Offshore Containers-Design,

Construction, Testing, Inspection and Marking.54. IMO Circ 613 (MSC 860)

55. Lloyds Code for Lifting Appliances in a Marine Environment.

56. API RP 2A Recommended Practice for Planning, Designing and Constructing Fixed

Offshore Platforms

57. API Spec 2c Specification for Offshore Cranes

58. API RP 2D Recommended Practice for Operation and Maintenance of Offshore Cranes

59. API Spec 9a Specification for Wire Rope

60. API RP 9B Recommended Practice on Application, Care and Use of Wire Rope

61. AWS D1.1 Structural Welding Code – Steel for Oil Field Service




Page 50 August 1999

OTHER MANUALS

62. IICL Guide for Container Equipment Inspection

63. IICL Repair Manual for Steel Freight Containers

64. AMOG/ESSO Factors of Safety for Lifting Slings used in Offshore Supply Boat Operations

65. AMOG Investigation of Dynamic Amplification Effects During Offshore Lifting.

66. APPEA Guidelines for the Phase Out of ISO Shipping Containers67. APPEA Guidelines for the Inspection, Testing and Marking of Offshore Containers

68. AMSA Australian Offshore Vessel Code of Safe Working Practice.

IICL: Institute of International Container Lessors Ltd.

Note: References 62 and 63 have been prepared for International Shipping Containers and not

Offshore Containers. They do however provide a good general guidance for containers.




____________________________________________________________________________ August 1999 Page 51

APPENDIX B

DEFINITIONS




Page 52 August 1999

Alter: To change the design of, add to or take away from the equipment where the

change may affect health and safety, but does not include routine

maintenance, repairs or replacements.

AMSA: Australian Maritime Safety Authority.

Approved: Approved by the Operating Company, regulator, authority or society.

AS: Australian Standard.

Asset Owner: Entity that owns “Lifting Equipment”.

Certificate of

Conformity:

Certificate issued by a facility accredited by NATA to inspect and test

containers to APPEA requirements. The issuance of this certificate

indicates to owners, users and transporters of the container that the unit is

“fit for intended service”.

The certificate is only to be issued when the accredited facility has ensured

that the container meets all the requirements detailed in APPEA Container

management documents.

Where there is an existing doubt, the NATA accredited facility should

recommend to the equipment owner that a qualified structural engineer

verify container design against the APPEA document.

Certified visual

inspection:

Inspection of “Lifting Equipment” accompanied by a report bearing the

endorsement stamp of the appropriate inspection body or classification

society. The inspection must be signed by an endorsed signatory. It

typically includes visual, material dimensional, and material thickness

checks, opening up and dismantling as considered necessary by theInspector may be required.

COG: Centre of gravity.

Competent

Person:

A person having practical and theoretical knowledge and relevant

experience, such as will enable that person to detect and evaluate any

defects and weaknesses that may affect the intended performance of the

equipment.

Container: “Lifted Equipment” used in lifting and transport operations (see Section

1.2).

Crane: An appliance intended for raising or lowering a load and moving it

horizontally. Detailed definitions for each type of crane are given in

AS 2549.

DAF: Dynamic Amplification Factor.

Designated

Inspector/

Surveyor/

Verifying body:

A representative of a Classification Society or an inspection body or a

verifying body registered with the statutory body to perform certain surveys

or inspections and issue certificates of inspection on behalf of the Statutory

Authority.

DME: Department of Minerals and Energy.




____________________________________________________________________________ August 1999 Page 53

Engineer: A person qualified to be a Member of the Institute of Engineers, Australia

(MIE Aust.) or recognised equivalent who is competent and has adequate

experience to assure that the technical requirements of this standard are

met.

Engineered Lift: A lift which due to constraints, circumstances or specialised engineering

input is beyond the scope of these guidelines. An engineered lift will

typically require modification to acceptance criteria and will thereforerequire a higher level of management and possible app0roval from the

relevant authorities prior to being carried out.

Equipment

Container:

Enclosure or frame designed specifically for lifting a particular item of

equipment or containing permanent fixtures such as a workshop. The

container with contents remains at a constant mass and centre of gravity

and would normally have dedicated rigging attached via padeyes. It

includes drilling support equipment, welding units, air compressor units

and workshops.

Gross Mass: The maximum permissible combined weight of a cargo container and its

contents, i.e. Maximum Gross Mass = Tare Weight + Net Weight measured

in kilograms (This is also known as Gross Weight measured in kilograms).

IMO: International Maritime Organisation.

Inshore Lift: Lifting to or from a vessel at a sheltered wharf. This may be performed

using either a vessel based or a shore based crane.

Inspection

“body”:

An organisation accredited by the National Association of Inspection

Authorities (Australia) to perform certain types of inspections and issueendorsed reports. These reports meet the requirements of the P(SL)A

schedule for test reports.

Inspector: Any person carrying out inspection of “Lifting Equipment”. Examples of

Inspectors are representatives of NATA accredited establishments, riggers,

crane drivers, welders, NDT technicians, QC inspectors, QC managers and

qualified engineers. The qualifications of the Inspectors are dependent on

the type of inspection being performed. In all cases, the Inspector shall

have experience and training suitable to the inspection being performed.

Where inspections referred to in this document require specific

qualifications, these have been given in the appropriate section.

Lifted

Equipment:

Equipment that the rigging connects to (Refer to Section 1.2). In the case of

machinery, valves, etc with attached padeyes, This term refers to the

machinery or valve.

Lifting Device: An item equipped with mechanical means for moving or placing a freely

suspended load.

Lifting

Equipment:

Means an item or an integrated assembly of items designed to convey or for

use in conveying people, equipment or materials and includes “Lifting

Gear” and “Lifting Devices”. It also may be referred to as materialshandling equipment.




Page 54 August 1999

Lifting Gear: An item of equipment for use with a “Lifting Device” for lifting people,

equipment or materials. The item is designed to be detachable from the

crane and includes both rigging and “Lifted Equipment”.

Lifting Points: Points on a structure to which rigging is attached, such as padeyes.

Lift Weight: Maximum gross weight of the container and its cargo

Maintenance: The activity of monitoring, inspecting, testing, refurbishing and replacing

of plant and equipment within its pre-existing design specifications.

May: Indicates a discretionary action.

MBL: Minimum breaking load.

MO: Marine Orders.

MODU: Mobile Offshore Drilling Unit.

MPI: Magnetic particle inspection.

NATA: National Association of Testing Authorities Australia.

NDT: Non-Destructive testing, including magnetic particle, ultra sonics.

Net Weight: The maximum permissible weight of the contents of a container in

kilograms.

New Container: Container constructed after the issue date of this document.

NTDME: The Northern Territory Department of Minerals and Energy.

Offshore

Container:

Container designed for the movement of equipment or materials to, from

and at offshore installations or at onshore locations.

Offshore Lift: A lift performed in unsheltered waters between two vessels, between a

platform and a vessel, or between a platform and the seabed.

Onshore Lift: Lifting about an onshore location not involving a vessel.

Proof Load: The test load required by the Code or Standard for the specific equipment.

Responsible

Person:

A person who is responsible to any one of:

• the designer of the equipment

• the manufacturer of the equipment

• a competent testing establishment

• the owner of the equipment

• a classification society

• the operating company

for carrying out design, testing, inspection, certification or determination of

safe working loads of “Lifting Equipment”.

Rigging: Equipment which is designed for repetitive use, to be readily detachable




____________________________________________________________________________ August 1999 Page 55

from a “Lifting Device” and which constitutes all or part of a lifting

assembly that connects a load to the “Lifting Device”.

Safe Working

Load (SWL):

The maximum gross load which may be imposed for a specific use in order

to allow an adequate margin of safety. The SWL may equal but never

exceed the working load limit (WLL),

e.g. In AS 1418 part 1 for Class 3 load applications, the SWL =

WLL, for Class 4 and 5 applications, the SWL = 0.8 WLL.Safe working load of a crane is the maximum mass which is permitted to

be safely handled by the crane. Safe working load of a lifting attachment

is the maximum mass that is permitted to be safely handled by the lifting

attachment.

Shall: Indicates a mandatory requirement.

Should: Indicates a recommended requirement.

Sling Angle: The angle the sling makes with the horizontal. Typically within the range

of 60 to 90 degrees.

Statutory

Authority:

An Authority having statutory powers to control the design, manufacture,

use and testing of “Lifting Equipment” in the State or Territory within the

Commonwealth of Australia in which the equipment is used.

Tare Weight: The weight of an empty container or the weight of a lifting beam or lifting

frame, complete with dedicated components, in kilograms.

Testing: Testing, in the context of inspection, means such tests carried out

periodically by a responsible person, in conjunction with inspection, at periods defined by this document.

Testing “body”: An organisation accredited by the National Association of Testing

Authorities (Australia) to perform certain types of tests and issue endorsed

reports. These reports meet the requirements of the P(SL)A schedule for

test reports.

Visual

Inspection:

A detailed visual examination and other such measures considered

necessary by an Inspector to determine the condition of the “Lifting

Equipment”. Inspection may include visual, dimensional.

WADME: The Western Australian Department of Minerals and Energy.




Page 56 August 1999




____________________________________________________________________________ August 1999 Page 57

APPENDIX C

OFFSHORE WIRE ROPE AND CHAIN SLINGS




Page 58 August 1999

REFER AS1666 FOR “ONSHORE/PLATFORM LIFTS”

2 3 4 5 6 7 8 9 10 11 12

Direct

Loaded Round Rectangular

load load

- - - 0 60 90 120 0 60 90 120

Rc 1 0.75 0.5 2 1.73 1.41 1 1 0.87 0.71 0.5

Rt 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95

Rm 1 1 1 1 1 1 1 1 1 1 1

Ro

Nominal Minimum

diameter breaking

force

mm kN

10 44 0.73 0.55 0.36

11 53.2 0.88 0.66 0.44

12 63.3 1.05 0.79 0.52

13 74.3 1.24 0.93 0.62

14 86.2 1.4 1.07 0.7116 113 1.8 1.4 0.94

18 143 2.3 1.7 1.19

20 176 2.9 2.2 1.4

22 213 3.5 2.6 1.7

24 253 4.2 3.1 2.1

26 297 4.9 3.7 2.4

28 345 5.7 4.3 2.8

32 450 8.1 5.6 3.7

Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL), Refer Section 5.4

Shaded Lift Configurations are not recommended for "Offshore Boat Lifts"

See Note Below

Rope

Safe Working Load, t

Round load Other than round load

Included Angle (a)

Loading Factors

TABLE C1

WITH 1570 GRADE WIRE AND FIBRE-ROPE CORE WITH FERRULE-SECURED EYES

1

Method of Loading

Choke Hitch Basket Hitch

SAFE WORKING LOADS FOR TABLE "OFFSHORE BOAT LIFT" USE OF SINGLE-PART SINGLE-LEG SLINGS




____________________________________________________________________________ August 1999 Page 59


2 3 4 5 6 7 8

0 to 60 90 120 0 to 45 0 to 60 0 to 45 0 to 60

Rc 1.73 1.41 1

Rt 0.95 0.95 0.95

Rm 1 1 1

Ro

Nominal Minimum

diameter breaking

force

mm kN

10 44 1.27 1.03 0.73

11 53.2 1.53 1.25 0.88

12 63.3 1.82 1.49 1.05

13 74.3 2.1 1.75 1.24

14 86.2 2.4 2.0 1.43

16 113 3.2 2.6 1.88

18 143 4.1 3.3 2.3

20 176 5.0 4.1 2.9

22 213 6.2 5.0 3.5

24 253 7.8 5.9 4.2

26 297 9.9 7.3 4.9

28 345 11.5 9.2 5.7

32 450 15.0 12.2 8.1

Note:


The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL),refer to section 5.4

17.4

11.5

13.3

7.5

9.8

4.7

5.8

2.8

3.7

2.1

2.4


1.47

1.77

Included Angle (a)

Loading Factors

2 0.87

0.95 0.95

1 1

See Note Below

Rope

Method of Loading

Direct loaded

Choke hitch

Round loadOther than

round load

1

TABLE C2

SAFE WORKING LOADS FOR "OFFSHORE BOAT LIFT" USE OF

TWO LEG , THREE LEG AND FOUR-LEG SLINGS

WITH 1570 GRADE WIRE AND FIBRE CORE WITH FERRULE-SECURED EYES




Page 60 August 1999


2 3 4 5 6 7 8 9 10 11 12

Direct

Loaded Round Rectangular

load load

- - - 0 60 90 120 0 60 90 120

Rc 1 0.75 0.5 2 1.73 1.41 1 1 0.87 0.71 0.5

Rt 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95

Rm 1 1 1 1 1 1 1 1 1 1 1

Ro

Nominal Minimum

diameter breaking

force

mm kN

10 63.1 1.05 0.79 0.52

11 76.3 1.27 0.95 0.63

12 90.8 1.51 1.13 0.75

13 107 1.78 1.34 0.8914 124 2.0 1.55 1.03

16 161 2.6 2.0 1.34

18 204 3.4 2.5 1.70

20 252 4.2 3.1 2.10

22 305 5.0 3.8 2.5

24 363 6.0 4.5 3.0

26 426 7.5 5.3 3.5

28 494 9.4 6.2 4.1

32 646 12.5 9.1 5.3

36 817 15.8 11.8 7.1

40 1010 19.5 14.6 9.7

44 1220 23.6 17.7 11.8

48 1450 25.0 21.0 14.0

52 1710 - 24.8 16.5

56 1980 - 25.0 19.1

60 2270 - - 21.9



Loading Factors

See Note Below

Rope


Basket Hitch


Included An le (a)

TABLE C3


WITH 1770 GRADE WIRE AND FIBRE-ROPE CORE WITH FERRULE-SECURED EYES

1

Method of Loading

Choke Hitch




____________________________________________________________________________ August 1999 Page 61


2 3 4 5 6 7 8

0 to 60 90 120 0 to 45 0 to 60 0 to 45 0 to 60

Rc 1.73 1.41 1Rt 0.95 0.95 0.95

Rm 1 1 1

Ro

Nominal Minimum

diameter breaking

force

mm kN

10 63.1 1.82 1.48 1.05

11 76.3 2.20 1.79 1.27

12 90.8 2.62 2.13 1.51

13 107 3.1 2.52 1.78

14 124 3.6 2.9 2.0716 161 4.7 3.8 2.68

18 204 5.9 4.8 3.4

20 252 7.8 5.9 4.2

22 305 10.2 7.7 5.1

24 363 12.1 9.9 6.1

26 426 14.2 11.6 7.5

28 494 16.5 13.4 9.5

32 646 21.6 17.6 12.5

36 817 25.0 22.3 15.8

40 1010 - 25.0 19.5

44 1220 - - 25.0

Note: The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL),

refer to section 5.4


-

-

-

19.1

25.0

14.0

16.5

9.7

11.8

5.4

7.1

3.6

4.1

2.54

3.0

See Note Below

Rope


2.10

0.95 0.95

1 1

Included Angle (a)

Loading Factors

2 0.87

WITH 1770 GRADE WIRE AND WIRE-ROPE CORE WITH FERRULE-SECURED EYES

1

Method of Loading

Direct loaded

Choke hitch


round load

TABLE C4






Page 62 August 1999


2 3 4 5 6 7 8 9 10 11 12

Direct

Loaded Round ectangular

load load

- - - 0 60 90 120 0 60 90 120

Rc 1 0.75 0.5 2 1.73 1.41 1 1 0.87 0.71 0.5

Rt 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95

Rm 1 1 1 1 1 1 1 1 1 1 1

Ro

Nominal Minimum

diameter breaking

force

mm kN

10 58 0.96 0.72 0.48

11 70.1 1.17 0.87 0.58

12 83.5 1.39 1.04 0.69

13 98.4 1.64 1.23 0.82

14 114 1.9 1.42 0.95

16 148 2.4 1.8 1.23

18 187 3.1 2.3 1.56

20 231 3.8 2.8 1.90

22 280 4.6 3.5 2.3

24 333 5.5 4.1 2.7

26 391 6.7 4.8 3.2

28 454 8.2 5.6 3.7

32 594 11.5 8.0 4.9

36 751 14.5 10.9 6.3

40 929 17.9 13.4 8.5

44 1122 21.7 16.2 10.8

48 1334 25.0 19.3 12.9

52 1573 - 22.8 15.2

56 1821 - 25.0 17.6

60 2088 - - 20.2




Included Angle (a)

Loading Factors

See Note Below

Ro e


Method of Loading

Choke Hitch Basket Hitch


TABLE C5


1




____________________________________________________________________________ August 1999 Page 63


2 3 4 5 6 7 8

0 to 60 90 120 0 to 45 0 to 60 0 to 45 0 to 60

Rc 1.73 1.41 1

Rt 0.95 0.95 0.95

Rm 1 1 1

Ro

Nominal Minimum

diameter breaking

force

mm kN

10 58 1.67 1.36 0.96

11 70.1 2.02 1.65 1.17

12 83.5 2.41 1.96 1.39

13 98.4 2.8 2.31 1.64

14 114 3.3 2.7 1.90

16 148 4.3 3.5 2.47

18 187 5.4 4.4 3.1

20 231 6.9 5.4 3.9

22 280 9.2 6.8 4.7

24 333 11.1 8.7 5.6

26 391 13.1 10.6 6.7

28 454 15.2 12.3 8.3

32 594 19.9 16.2 11.536 751 25.0 20.5 14.5

40 929 - 25.0 17.9

44 1122 - - 21.7

Note:



The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL),


25.0

25.0

-

17.5

23.0

12.8

15.1

8.5

10.8

4.9

6.3

3.3

3.8

2.34

2.8

See Note Below

Rope


1.93

0.95 0.95

1 1

Included An le (a)

Loading Factors

2 0.87

1

Method of Loading

Direct loaded

Choke hitch


round load

TABLE C6



The operational Loading Factor, Ro, is determined as a function of lifting weight (SWL),

Refer Section 5.4Shaded Lift Configurations are not recommended for “Offshore Boat Lifts”




Page 64 August 1999


1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Stra ight Adjustable Reeved

Sling Sling Sling

- - - 60 90 120 60 90 120 60 90 120 -

Rc 1 0.75 0.75 1.73 1.41 1 1.30 1.06 0.75 1.30 1.06 0.75 1.5

Rt 1 1 1 1 1 1 1 1 1 1 1 1 1

Rm 1 1 1 1 1 1 1 1 1 1 1 1 1

Ro

Minimum

Non- breaking

preferred force

(mm) (mm) (in) k N

10 126.0 2.21 3.8 3.1 2.21

11 158 2.77 4.8 3.9 2.7

12 197 3.46 5.9 4.8 3.4

1/2 203 3.57 6.2 5.0 3.5

13 213 3.7 6.6 5.2 3.7

14 248 4.3 8.2 6.1 4.3

5/8 317 5.5 11.4 8.7 5.5

16 322 5.6 11.6 8.9 5.6

18 408 7.6 15.2 12.0 7.6

3/4 457 9.0 17.3 13.7 9.0

20 503 10.4 19.4 15.2 10.4

22 621 13.1 25.0 19.5 13.1

24 631 13.3 - 19.9 13.3

25 724 15.6 - 23.6 15.6

1 786 17.2 - 25.0 17.2

27 811 17.8 - - 17.8

28 917 20.7 - - 20.7

30 986 22.6 - - 22.6

1 1/4 1267 25.0 - - 25.0

No te: The ope rational Loading Factor, Ro, is de termined as a function of lifting weight (SWL), Refer Section 5.4Sling Types in shaded region are not recommended for Offshore Lifts

SAFE WORKING LOADS FOR "OFFSHORE BOAT LIFT" USE OF SLINGS

TABLE C7

Method of Loading

Single Leg Slings Slings of 2,3 or 4 legs Endless Slings

Straight Sling Reeved Sling Basket/Reeved Sling

Included Angle (a)

Loading Factors

See Note Below

Chain

Safe Working Load, tSize (as designated by AS232 1)

Preferred Temporary

WITH GRADE T CHAIN




____________________________________________________________________________ August 1999 Page 65

APPENDIX D

DYNAMIC AMPLIFICATION FACTOR




Page 66 August 1999

FIGURE D.1 RECOMMENDED DYNAMIC AMPLIFICATION FACTOR(DAF)

0

0.4

0.8

1.2

1.6

2

2.4

2.8

3.2

0 5 10 15 20 25

Lifted Mass (tonnes)

D y n a m i c A m p l i f i c a t i o n F a c t o r ( D A F )




____________________________________________________________________________ August 1999 Page 67

APPENDIX E

CONTAINER MARKING EXAMPLE




Page 68 August 1999

FIGURE E.1 INSPECTION DATA PLATE

215

35 180 (6 x 30)

INSPECTION DATA – OFFSHORE CONTAINER

Container No.

Maximum Gross Mass kg @ deg. Sling angle

Tare Mass kg

Payload Container kg

Intermediate deck kg

Owner:

Tel. No. +

+

+

TEST PROOF LOAD NDT VISUAL

INSPECTION

INTERVAL 6 YEAR TEST 3 YEAR TEST 1 YEAR TEST

DATE CERT NO DATE CERT NO DATE CERT NOAT

MANUFACTURE

AT

SITE

1.5 mm STAINLESS STEEL 5 mm LETTERING

Suggested plate incorporates ideas from international documents and local

requirements. All dimensions are shown in mm.

250 mm

70 mm

10 mm LETTERING




____________________________________________________________________________ August 1999 Page 69

FIGURE E.2 IDENTIFICATION PLATE

215 mm

OFFSHORE CONTAINER

Name of Manufacturer

Month/year of Manufacture

Manufacturer’s serial No.

Maximum Gross Mass kg @ deg. Sling angle

Tare Mass kgPayload Container kg

Intermediate deck kg

Certificate of Conformity No.

Design Temperature oC

The suggested plate is in line with international document requirements.

1.5 mm STAINLESS STEEEL

150 mm

10 mm LETTERING5 mm LETTERING




Page 70 August 1999

FIGURE E.3 OPERATIONAL MARKING PLATE

ID No TW-SS01

OWNER WOODSIDE

MANUFACTURER DISON

DATE OF

MANUFACTURE

12/96

TYPE OFFSHORE EQUIPMENT CONTAINER

All dimensions shown are in mm.

200

2mm Stainless steel plate

90

6.4 TY




____________________________________________________________________________ August 1999 Page 71

FIGURE E.4 IDENTIFICATION NUMBER

Needs to be 75mm minimum lettering to comply with

international document requirements ⁄ ⁄⁄ ⁄

PW - SS01

All dimensions shown are in mm.

VARIES

6.3 70 6.2 50




Page 72 August 1999




____________________________________________________________________________ August 1999 Page 73

APPENDIX F

INSPECTION & TESTING REQUIREMENTS




Page 74 August 1999

TABLE F.1

INSPECTION AND TESTING REQUIREMENTS FOR LIFTING DEVI

P

ITEM

REFERENCE

CERTIFIED

VISUAL

INSPECTION

NDT FREQU

Cranes

(The various types of cranes and

lifting appliances are listed in

AS 1418)

Onshore/Inshore:

• AS 1418 (Parts 1 to 17)

• AS 2550

• MO 32

• State Acts & Regulations

• Manufacturer’s Specs

Offshore:• API Spec 2C

• BS 2573

• Lloyds Code for Lifting

Appliances in a Marine

Environment

• Manufacturer’s Specs

1 Year

Subject to:

• Visual inspection

• Failure Mode

Analysis

• Individual

Company Program

• Initial Certifica

• Following Repa

Subject to:

• Visual inspectio

• NDT

• Individual Com

MO32 specifies eve

Individual State Reg

every 12 months for

Overhead Padeyes AS1418.1 & .2

MO 32

1 Years *

Subject to visual

inspection or every 3

years

Initial test and then

inspection, NDT and

company program.

Forklift tynes AS 2359 1 Year

Subject to visual

inspection

Initial test and then

inspection, NDT andcompany program.

Mono rails P(SL)A AS1418.1 & .2 1 Years * Initial NDT, then

subject to visual

inspection

Subject to individua

program

Note: * Certified Visual Inspection includes permanent marking of SWL



APPEA

August 1999 Page 75

TABLE F.2

INSPECTION AND TESTING REQUIREMENTS FOR LIFTED EQUIPM

Notes:

1.

This table applies to “Lifted Equipment” up to 25

*

tonnes Gross Weight that has a Certificate of Conformity.2.

“Lifted Equipment” should be tested using their own dedicated rigging gear (lifting set).

3. “Lifted Equipment” above 25* tonnes Gross Weight may be proof load tested as specified by the design engineer.

P

ITEM

REFERENCE

CERTIFIED

VISUAL

INSPECTION

NDT FREQUENC

“Lifted Equipment”

(Includes all types of offshore containers,

baskets, skids, skips, spreader beams,

spreader frames, workshops, lab

containers, specialised items such aswork boxes, drilling guide bases,

conductor casing joints, etc.)

APPEA 1 year

• Initial Certification Test

• Every 3 years thereafter

• Following repairs to

structural members

• Subject to visual inspection


• Every 6 years th

• Following repa

structural memb

• Subject to visua

inspection

Tanks for Fluids

(Includes tanks/containers of all sizes for

both normal and dangerous cargoes)

APPEA 1 year


• Every 3 years thereafter

• Following repairs to

structural members

• Subject to visual inspection


• Every 6 years th

• Following repa

structural memb

• Subject to VisuInspection

Personnel Baskets

(Including Dedicated Rigging)

APPEA 1 year

N/A • Initial Certifica

• Every 1 year

• Subject to visua

inspection

* Arbitrarily selected limit for “Engineered Lifts”




Page 76 August 1999

TABLE F.3

INSPECTION AND TESTING REQUIREMENTS FOR RIGGING

Notes:1.

Offshore containers shall have specifically designed lifting sets, which shall not be removed from the container except for re

of the container.

2.

For Safety Factors for Rigging Equipment used in Offshore Lifting Operations refer to section 5.4.

3.

Minimum chain diameter to be 10mm. For containers with Gross Weight more than 3500kg, the minimum chain diameter m

4. Min. Wire Rope diameter to be 13mm. For containers with Gross Weight more than 3500kg, the minimum wire rope diame

PRO

ITEM

REFERENCE

CERTIFIED

VISUAL

INSPECTION

NDT FREQUENCY

Loose Rigging

(Includes all types wire and synthetic ropes, chains, links,

shackles, swivels, rings, sockets,

hammerlocks, etc)

APPEA • Not Required

• 3 monthly visualinspections

• Colour coding

• Visual inspectioneach time before use.

Subject to visual

inspection


• Subject to company program.

Lifting Sets

(Includes wire rope and chain

sets, complete with all

associated accessories)

APPEA 1 year

as part of the container

inspection.

Subject to visualinspection.


• Offshore – Every 6

years as part of the

“Lifted Equipment”

Proof Load Test.

Crane Hooks APPEA 1 year

• Every 2 years

• Subject to Visual

Inspection





August 1999 Page 77

APPENDIX G

GUIDE TO AUSTRALIAN AND INTERNATIONAL STANDARDS




Page 78 August 1999

Table G1- Guide to Australian and International Standards

Note: This table is intended as a guide only. In many cases, requirements of International standards will be less onerous than Austr

than Australian standards are not recommended to be adopted without specific Operator approval.

Aust/NZ No Australian/New Zealand Title ANSI Standard British Standard

AS ISO-1000 The International System of Units - BS 5555 -

AS 1138 Thimbles for Wire Rope - BS 464

BS 3226

Rules f

Part 2 C

AS 1171 Non-Destructive Testing Magnetic

Particle Testing of Ferromagnetic

Products, Components and Structures

- BS 6072 -

AS 1353 Flat Synthetic Webbing Slings - BS 3481

BS 5053

-

AS 1380 Fibre Rope Slings - BS 2052

BS 4921

BS 7648

-

AS 1418 Cranes (Including Hoists & Winches) ASME B30API RP2D

Spec 2C

BS 327BS 357

BS 466

BS 1757

BS 2452

BS 2573

BS 2799BS MA41

BS MA79

Rules fLifting

AS 1438 Wire - Coil Flat Slings - - -

AS 1504 Fibre Rope - Three Strand Hawser

Laid

- - -

AS/NZS 1554 Structural Steel Welding AWS D1.1 BS 4870 -

AS 1657 Fixed Platforms, Walkways,

Stairways and Ladders - Design,

Construction and Installation

A1264.1 BS 4592

BS 5395

-

AS 1664 Aluminium Structures Code AWS D1.2 BS 8118 -



APPEA

August 1999 Page 79


BS CP118

AS 1666 Wire Rope Slings ASME B30.9 BS 1290 Rules f

Part 2 CAS 2089 Sheave Blocks of Maximum Lift 60

Tonne

- BS 4018

BS 4344

BS 4536

BS MA47

Rules f

Part 2 C

AS 2207 Non-Destructive Testing for

Ultrasonic Testing of Fusion Welded

Joints in Carbon & Low Alloy Steel

AWS C3.8 BS EN 1714 -

AS 2317 Collared Eyebolts ASME B18.15 BS 4278 -

AS 2318 Swivels for Hoists - - Rules f

Part 2 C

AS 2319 Rigging Screws and Turnbuckles - BS 4429 -

AS 2321 Short Link Chain for LiftingPurposes (Non Calibrated) ASME B29 BS 3113BS 3458

BSEN 818-1

BS 6304

Rules fPart 2 C

AS 2550 (1982) Cranes – Safe Use ASME B30 - Rules fLifting

AS 2741 Shackles - BS 3551

BS 6994

Rules f

Part 2 C

AS 2759 Steel Wire Rope - Application Guide API RP9B BS 6210

BS 6570

-

AS 3569 Steel Wire Ropes Spec 9A BS 183

BS 302

BS 525

Rules f

Part 2 C

AS/NZS 3678 Structural Steel – Hot Rolled Plates,Floor Plates and Slabs

SAE J763SAE J1392

BS 7613 -

AS/NZS 3679.1 Structural Steel – Part 1 : Hot Rolled

Bars and Sections

SAE J1442 BSEN 10210-2 -

AS/NZS 3679.2 Structural Steel – Part 2 : Welded I

Sections

- - -




Page 80 August 1999


AS 3775 Chain Slings – Grade T ASME B29 BS 2902

BS 6968

Rules f

Part 2 C

AS 3776 Lifting Components for Grade TChain Slings

- - Rules fPart 2 C

AS 3777 Shank Hooks and Large Eye Hooks -

Maximum 25 Tonne

ASME B30.10 BS 2903 Rules f

Part 2 C

AS 3990 Mechanical Equipment - Steelwork AISC BS 5950

BS 7608

DDENV 1993

DDENV 1994

-

AS 4048 Flat Pallets for Materials Handling

(1100mm x 1100mm suitable for use

in ISO Series 1 Freight Containers)

ASME MH BS 3810

BS 6637

BS M69

-

AS 4100 Steel Structures AISC BS 5950

BS 7608

DDENV 1993DDENV 1994

-

AS 4142 Fibre Rope - BSEN 698

BSEN 701

BSEN 1251

BS 7648

Rules f

Part 2 C

AS B291 Lifting Rings & Links - - Rules f

Part 2 C

AS/NZS 3711.1 Freight Containers:- Part 1

Classification, Dimensions & Ratings

ANSI MH BS 3951 -

AS/NZS 3711.2 Freight Containers:- Part 2 –

Terminology

ANSI MH BS 3951 -

AS/NZS 3711.3 Freight Containers:- Part 3 - Corner

Fittings

ANSI MH BS 3951 -

AS/NZS 3711.4 General Purpose Containers ANSI MH BS 3951 -

AS/NZS 3711.5 Thermal Containers ANSI MH BS 3951 -

AS/NZS 3711.6 Tank Containers ANSI MH BS 3951 -



APPEA

August 1999 Page 81


AS/NZS 3711.7 Dry Bulk Containers ANSI MH BS 3951 -

AS/NZS 3711.8 Platform Containers ANSI MH BS 3951 -

AS/NZS 3711.9 Coding, Identification and Marking ANSI MH BS 3951 -

AS/NZS 3711.10 Handling and Securing ANSI MH BS 3951 -




Page 82 August 1999



APPEA Guidelines for Lifting Equipment - Phase Out of ISO Containers

August 1999 Page 83

APPENDIX H

GUIDELINES FOR THE PHASEOUT OF ISO SHIPPING

CONTAINERS OFFSHORE






August 1999 Page 85

PREAMBLE

The purpose of this document is to provide a guideline for the inspection and testing of ISO shipping

containers used in the offshore oil & gas industry. ISO shipping containers are not designed for use in

the offshore industry where dynamic lifting forces apply.

These guidelines will remain in force until the target phase out date of 31/12/2000 is reached. Whilstthis is an industry target date, individual companies may require that ISO containers be removed from

service at an earlier date. In the interim this document will provide guidance for the management of

ISO containers including inspection, de-rating and testing requirements.

For design and fabrication of replacement containers the requirements of the draft APPEA “Guideline

for Lifting Equipment” should be used. The following section is extracted from the referenced document.




Page 86 August 1999

DOCUMENT SCOPE

Provision of procedures & guidelines to manage the use of ISO containers

used in the offshore industry.

The document provides guidelines for the inspection, testing and marking of ISO containers used in the transport of goods to and from offshore locations.

The use of the containers is to be managed in accordance with this document.

DOCUMENT SOURCE

& RECOGNITION Much of the information contained within the documents on ISO Containers

has been reproduced from Woodside Energy Ltd’s (WEL), King Bay Supply

Base, Lifting Equipment Management System.APPEA thank WEL for their contribution in permitting contents of their

documents to be reproduced herein.

IDENTIFICATION OF

“ISO” CONTAINERS ISO containers are the containers originally built for international shipping and fitted with ISO Corner fittings and lifted in container ports, from these fittings,

with a purpose built spreader frame and special “Twist-locks”.

Most are 20ft in length although 10, 30 & 40ft lengths are also available.

NOTE: It is possible for purpose built offshore containers to have ISO Corner

fittings.

This is quite acceptable, provided that these are only used for securing during

transport and/or onshore/inshore lifting in accordance with onshore/inshore

container lifting guidelines as detailed in AS 3711.10:1993 “Freight

Containers – Handling and Securing” and, are not used for offshore lifting.

CONTROLLED USE OF

ISO CONTAINERS

Containers used in international shipping are controlled by the International

Convention for Safe Containers (CSC).When the containers used in international and/or coastal shipping reach the

end of their service life, either through condition or a “time life” expiry they

are often sold off without current CSC compliance.

Any existing CSC compliance plate has no meaning in the offshore industry

except for a reference in de-rating the container as detailed within this

document.

The containers are designed and rated for use in still water ports and not for

offshore use where significant dynamic forces occur during lifting operations.

REFERENCE

MATERIAL

Marine Orders, Part 44, Section 11

International Maritime Organization Circular 613 (to be replaced by Maritime

Safety Committee, Circular 860)

International Convention for Safe Containers (CSC) IMO, 1982

DNV 2.7-1 Offshore Containers -Certification Notes.

AS3711.10 – 1993 - Freight Containers, Handling & Securing

APPEA “Guideline For Lifting Equipment.”




August 1999 Page 87

ALLOWABLE ISO

CONTAINER STYLES& LENGTHS

Closed roof, ISO containers up to 20 ft. in length will be accepted for offshore

transportation subject to meeting requirements of this document.Open top style, ISO containers and any ISO container over 20 ft in length will

not be accepted for offshore transportation.

MODIFICATIONS TO

ISO CONTAINERS

Any ISO container that has been modified from the original CSC design must

have engineering calculations to support the continued integrity of thecontainer.

Unlike a purpose built offshore container, which is designed to carry full load

on primary structure members, ISO containers rely on the integrity of wall

panels for primary strength.

Such modifications may include:

• Addition of extra doorway

• Alteration to length

PHASING OUT ISO

CONTAINERS FROM

OFFSHORE

INDUSTRY

Contractors currently utilizing ISO containers are expected to reduce the

number in use during the lead up to the phase out date and replace with

purpose built offshore shipping containers.

Advice regarding standards and guidelines to be followed for new designs will

be issued to the Australian offshore oil & gas industry by APPEA in

“Guideline for Lifting Equipment ” currently in draft form.

An extract from the draft APPEA Guideline is included on Page 2 of this

document.

“ISO” corner

fitting

Typical ISO

Container




Page 88 August 1999

COMMENTARY ON

LIFTING POINTS• Even in a still water port situation, ISO shipping containers cannot be

lifted from the ISO Corner fittings by shackles and slings. This applies

even when empty.

• Lifting with spreader frames as used in port situations is not allowed inoffshore lifting operations. Refer to clause 2.2 of IMO 613 (referred to in

Marine Orders Part 44.)

NOTE: IMO 613 will be replaced by a new Maritime Safety Committee

document “Guidelines for the Approval of Offshore Containers Handled in

Open Seas.” (MSC Circular 860) This document further emphasises that ISO

corner fittings are not to be used for lifting in offshore transport operations.

ISO containers used in the offshore industry should have padeyes that are

purpose built. Refer to “Padeyes” below.

PADEYE

REQUIREMENTS

The installation of padeyes must be carried out in accordance with good engineering practices.

• Design by qualified structural engineer.

• Design verification by independent engineer, who has not been involved

in the design.

• Carry MGW on 2 of four padeyes.

• Align to centre of gravity of the load to provide for the angle of the lifting

forces to be 45 degrees from the vertical.

• Shackle pin hole to be +3mm or, not greater than 4% more than the

shackle pin diameter.

• Width of padeye to be equal to 75% of the opening of shackle to be fitted.

This may be accomplished by fitting bosses to padeye.

• Material trace-ability.

• Documented welding procedures (To AS1554, AWSD1.1 etc.)

• Welder qualification trace-ability.

• NDT inspection of all welding associated with padeyes.

NOTES:

1. The installation of padeyes MUST have engineering trace-ability.2. DNV 2.7-1 provides full details of padeye design and material

requirements and designers are encouraged to use the DNV document as a

guide.

Shackles in ISOCorner fittings are not

permitted.

➚ Although not generally required whencontainer is down-rated, lifting with speciallifting beams will be allowed during phase out.

Must be fitted to padeyes as shown.




August 1999 Page 89

ALLOWABLE MGW

(Maximum Gross

Weight)

ISO Containers used in the offshore industry where significant dynamic forces

occur during lifting from supply vessels must be significantly de-rated.

Subject to satisfactory inspections as per Page 7, ISO container use, up to the phase out date, will be allowed under the following conditions:

• De-rated by multiplying original CSC Maximum Gross Weight (or Mass)

x 2 and dividing the figure by 5.

E.g. A 24 tonne MGW container x times 2 = 48 tonnes divided by 5 = 9.6

tonnes MGW.

MARKING

REQUIREMENTS

All ISO containers, original or modified, shall have:

• A stenciled marking beside the CSC data plates indicating “NotApplicable”. The plate should remain to indicate the original MGW that is

used in the de-rating formula above.

Marking plates are required for:

• Operational Marking Plate (Tare, Nett & Gross)

• Test Plate (date of test and inspections) NOTE: Refer to pages 9 & 10 for details of plates.“Other” marking requirements

• Each container should be marked with a unique identification number

issued by the owner.

Notes:

1. The above number should be cross-referenced on all relevantdocumentation.

2. The number should be prominently displayed on a minimum of 2 sides of

the container in contrasting colours with stenciled characters of not less

than 75 mm in height.

FORKLIFT POCKETS ISO Containers often have more than 1 set of forklift pockets. Extreme caution

should be used when lifting a laden ISO container from the forklift pockets.

If there are two sets, with one set being close to the centre of the container, the

inner set are designed for “Empty lifting only”. These words must be stenciled

on the base frame adjacent to forklift pockets when such forklift pockets are

installed. Stenciling to be 75mm in height.There are instances where ISO containers have been modified and appear to

have useable forklift pockets on more than two sides, this can be a dangerous

situation as forklift pockets have been found that have the fork tynes bearing

on a plywood floor. Check before using and at scheduled inspection.

SLINGS Sling sets may be chain or wire rope.• Four sling assemblies are preferred

• Minimum sling angle of 60 degrees to horizontal.

• Chain used in stingers (or 5th

leg) must meet ISO 3076, or ISO 7593

standards.

Note: The use of stingers is discouraged as the redundancy in a 4 leg assemblyis lost.

SHACKLES Shackles must be:

• Grade “S” minimum

Safety pin type with split pin fitted




Page 90 August 1999

CONTAINER

INSPECTIONS

ISO containers must receive a Thorough Visual Inspection both annually and

prior to any load testing.

• NDT Inspection of padeyes and floor support structure is to be carried out

annually and prior to load testing.

• All Thorough Visual Inspections and NDT must be recorded in a liftingequipment database.

THOROUGH VISUAL

& NDT INSPECTIONS

ANNUAL

REQUIREMENT

• Door latching mechanisms in good working order (where applicable)

• Container is free from obvious defects, corrosion, impact damage, cracks,

etc.

• Under-floor support structure inspection. The floor support structure is

very light in an ISO container and is prone to extensive corrosion and

cracking when used in the offshore environment.

• Place container on supports to allow full inspection of underside and

ensure adequate lighting.

• Look for corrosion and/or any cracking.• It may be necessary to sand blast corroded steel to allow full inspection.

• Suspected areas of cracking to have NDT inspections carried out.

• Steelwork that has suffered significant (greater than 10%) metal loss

through corrosion is to be replaced.

• Complete structure to be examined for corrosion, cracking, and impact

damage. Particular attention is to be given to inspection of lifting points

and corner post assemblies.

• Visually inspect all welds for defects.

• NDT all welds in padeye area. (NATA accredited NDT contractor

required)

• Inspect for signs of mechanical damage.

• Doors, frames, seals, hinges, locks should be examined and functionally

checked to ensure satisfactory operation without undue force.• Check floor is substantially flat with no signs of damage or other

indications that may indicate overloading. Any internal floor damage may

indicate underside damage- re-check.

• Marking Plates should be as per requirements of this document (pages 9

& 10).




August 1999 Page 91

VISUAL INSPECTORS

KNOWLEDGE

REQUIREMENTS

The visual inspector should have, as a minimum, a knowledge and adequate

practical experience of:

• The statutory requirements relating to containers.

• The provisions of DNV 2.7-1 (to be used as a guide only as ISO

containers do not comply with offshore container standards).• The various types of containers in service.

• The correct methods of slinging and handling the containers.

• The loads affecting containers when handled under adverse offshore

conditions, particularly those affecting lifting points and, in the case of

ISO containers used offshore, the floor support structure.

• The methods of testing containers as detailed in Maritime Safety.

Committee circular 860 or, DNV2.7-1 Offshore Container, Certification

Notes.

• Defects likely to be found in containers and acceptable levels of wear,

distortion and deterioration in relation to safety in use.

• Welding methods and procedures and qualification of welders.

•

The various methods of non-destructive testing (NDT) and a good understanding of how they work and their limitations

• Procedures for measuring container to ensure distortion has not occurred

during service or load testing.

TESTING AN ISO

CONTAINER

As all ISO containers will be phased from the Australian offshore oil & gasout by 30/12/99 it is proposed that any containers currently in use undergo the

following load test (subject to satisfying inspection requirements) which

would see them through to phase out date.

• Testing of container as per “Testing Requirements” as detailed in IMO

613 & MSC 860. (Drop test will not be required)

TESTING

PROCEDURES

Prior to load testing, carry out Thorough Visual Inspection as detailed withinthis document.

(There is no value in testing a container that has defects)4 Point Lifting Test:

Internal Load (not to be hung under container): a uniformly distributed load,

such that the combined tare of the container and test load is equal to 2.5 timesthe de-rated MGM.

The container should be lifted with its lifting set attached to all four padeyes.

2 Point Lifting Test:

Internal load (not to be hung under container): a uniformly distributed load

such that the combined tare of the container and test load is equal to 1.5 times

the de-rated MGM. It may be necessary to secure the weights to prevent

slippage during testingThe container should be lifted with slings attached to two diagonally opposite

padeyes during the test.

Drop Test:

IMO 613 and DNV 2.7-1 require that containers be drop tested when

approving type designs. APPEA does not require that ISO design containers bedrop tested but the requirement will need to be met when type testing future

new container designs.




Page 92 August 1999

ALLOWABLE

DEFLECTIONDURING &

SUBSEQUENT TO

LOAD TESTING

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

COMMENTS ON

DEFLECTION

LIMITS

Where deflection exceeds the maximum allowable limit, the container should

be scrapped.

Offshore Container Identification Plate

OFFSHORE CONTAINER

Name of Manufacturer (if known) Month/year of Manufacture (if known)

Manufacturers Serial No. (if known)

Maximum Gross Weight Kg at deg sling angle

Tare Weight Kg

Payload Container Kg

IDENTIFICATION

PLATE MATERIAL &

SIZE

REQUIREMENTS

• Plates to be of stainless steel, 1 .5 mm thick

• Affixed with stainless steel rivets (not aluminium)• 215 mm overall width

• 150 mm overall height

• Main heading alpha characters to be stamped 10mm in height

• Other alpha & numeric characters 5mm in height




August 1999 Page 93

Offshore Container Inspection Data Plate

INSPECTION DATA-OFFSHORE CONTAINER

Container No.

Maximum Gross Weight KgTare Weight KgPayload - Container Kg Mid- deck (Not Applicable to ISO containers)

Owner:Tel. No. +

Test Proof Load NDT Visual Inspection

INTERVAL ONCE ONLY 1 YEAR 1 YEAR

DATE &“ TESTED BY”

Note: The inspection frequencies shown above only apply to ISO containers

INSPECTION DATA

PLATE MATERIAL &

SIZE

REQUIREMENTS

• Plate to be of stainless steel, 1 .5 mm thick

• Affixed with stainless steel rivets (not aluminium)

• 215 mm overall width

• 250 mm overall height• Main heading alpha characters to be stamped 10mm in height





Page 94 August 1999

OK No

• Container was placed on supports and a full

underside inspection carried out.

• Container has no significant corrosion and/or structural faultaffecting integrity

• Container floor is in sound condition

• NDT of padeye welds and floor support structure

has not revealed any cracking (or repairs have

been effected)• Padeyes are fitted to the container

• Padeyes have engineering design drawings available

• Padeye design complies with the requirements of this

document.

• Container has been de-rated as per requirements of this

document

• Container has been load tested as per requirements of thisdocument

• There is no permanent distortion of the container following

load testing

• Forklift pocket marking is as per the requirements of this

document and the pockets are in a good and safe condition.

• Where a 5th

leg is used in a chain sling assembly, the chain in

the 5th

leg must meet ISO3076 standards for lifting chain.

CHECK LIST.

REVIEW PRIOR TO

ISSUING A TESTCERTIFICATE

• Engineering drawings and structural analysis support any

modifications. All such modifications should have

independent design verification.




August 1999 Page 95

APPENDIX I

GUIDELINES FOR THE INSPECTION, TESTING AND

MARKING OF OFFSHORE CONTAINERS



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

Page 96 August 1999

PREAMBLE

The purpose of these guidelines is to address integrity requirements for existing offshore containers.

The guideline does not address requirements for new container fabrication. For information on new container

fabrication, refer to APPEA “Guidelines for Lifting Equipment”

Neither do these guidelines address concerns with the use of ISO containers within the offshore industry. For

ISO container management, refer to the APPEA Guideline for the Phase Out of ISO Shipping Containers.

These guidelines will provide guidance to lifting equipment testing facilities on consistent minimum quality

requirements for testing offshore containers.

APPEA encourages all offshore container owners and their agents to utilise inspection services that have been

accredited by NATA (or equivalent overseas organisations) to carry out inspections and/or tests in accordance

with this guideline.

If the required documentation needed to obtain a “Certificate of Conformity” as detailed within this guideline

is not available to support the integrity of the container to be inspected and/or tested, the container should not

be approved for offshore use. This may require that engineering drawings be developed and calculations

carried out to verify the design of the container as being fit for intended service. Without all required

information, a “Certificate of Conformity” should not be given for the container.




August 1999 Page 97

DOCUMENT SCOPE Provide guidelines for the inspection, testing and marking of a widerange of containers, baskets, skips etc. used in the offshore oil & gasindustry.

INTRODUCTION The range of shapes, sizes and capacity of containers used in theoffshore industry makes it difficult to specify all requirements that need

to be met for each individual design.This document will provide specifics on some matters affecting safetyof containers whilst other areas may offer guidance only.It is the joint responsibility of both the equipment owner and theinspection and/or testing facility to ensure that all containers used

within the offshore industry are fit for the intended service.

REFERENCE

MATERIALAustralian Maritime Safety Authority, Marine Orders, Part 44, Section11

International Maritime Organization Circular 613 (to be replaced byMaritime Safety Committee, Circular 860)

DNV 2.7-1 Certification notes for Offshore ContainersAPPEA Guidelines for Lifting Equipment IMDG Code

PrEN12079. Offshore Containers – Design, construction, testing,inspection and marking.Petroleum Submerged Lands Act P(SL)AZOCA Regulations

COMMENTS ON

DESIGN OF

OFFSHORE

CONTAINERS

APPEA has recognised that there are many containers in use within the

Australian offshore oil & gas industry that may not be correctlyengineered for the service.The guidelines and procedures provided in this document will assist inensuring that every container used within the industry has engineeringdrawings and design calculations to support the Maximum GrossWeight indicated on the container.Without the required documentation the testing facility will have noready method of determining if the Maximum Gross Weight (MGW)nominated by the owner, is in fact a safe working load to be applied. New containers being fabricated will be to more stringent guidelinesand will be built to recognised standards such as DNV 2.7-1. This willautomatically provide the quality that this document seeks to introduceto existing containers.

JUSTIFICATION OF

ALLOWABLE MGW

(Maximum Gross

Weight) OF EXISTING

CONTAINERS

Existing containers may well need to be down-rated due to the morestringent testing now required.It is recommended that container owners carry out a review of existingdesign MGW ratings to ensure that the container(s) will meet thetesting requirements of 2.5 times MGW.

It may be necessary to revise the container MGW and to update

drawings as required, indicating new ratings.




Page 98 August 1999

PADEYE

REQUIREMENTS

One of the most critical areas in the fabrication of an offshore container is the

padeyes and their attachment to the container. For this reason APPEA requires

that the following be met on all offshore containers.

The installation of padeyes must be carried out in accordance with good

engineering practices.• No “bolted on” padeyes are permitted

• Padeyes must be welded to the primary structure of the container

Note: For existing containers of mono-coque construction, a detailed

engineering assessment of the padeye connection is required.

• Design carried out by a qualified structural engineer and checked by an

independent engineer.

• For design purposes, the design load is to be carried on two diagonally

opposite padeyes.

• Align to centre of gravity of the loaded container.

• Shackle pin hole to be +3mm or, not greater than 4% more than the

shackle pin diameter

• Width of padeye to be equal to 75% of the opening of shackle to be fitted.This may be accomplished by fitting bosses (cheek plates) to padeye.

• Material traceability where appropriate material with through thickness

properties is to be specified. (Lamellar Defects)

• Documented welding procedures (To AS1554, AWSD1.1 etc.)

• Welder qualification trace-ability

• NDT inspection of welding by MPI for all fillet welds & a combination of

Ultra Sonic and MPI for full penetration welds. ( NATA to assist with text)

NOTES:

1. The installation of padeyes MUST have engineering trace-ability.

2. DNV 2.7-1 provides full details of container design and material

requirements and designers are encouraged to use the DNV document as a

guide.

GENERAL DESIGN

REQUIREMENTS• Mono-coque construction is not to be used in new offshore container

fabrication and/or designs. i.e.: A “Primary structure” is required.

• For all other design requirements for new offshore containers, refer toDNV2.7-1 “Certification Notes – Offshore Containers”.

.

MARKING

REQUIREMENTS

All Offshore containers shall have:

Marking plates for:

• Operational Marking Plate (Tare, Nett & Gross)

• Test Plate (date of tests and inspections)

“Other” marking requirements• Each container should be marked with a unique identification number

issued by the owner.

Notes:1. The above referenced “unique number” should be cross-referenced on all

relevant documentation, including the “Certificate of Conformity”.

2. The number should be prominently displayed on at least 2 sides of the

container in contrasting colours with stenciled characters of not less than

75 mm in height.




August 1999 Page 99

COMMENTS ON

LOAD TESTING OF

OFFSHORE

CONTAINERS

The load test requirements for offshore containers used in Australian waters

have traditionally been taken from Marine Orders Part 32 as published by the

Australian Maritime Safety Authority.

The APPEA lifting equipment guideline committee have recognised that this

table is not suited to offshore containers and further recognise that it is therequirements of the International Maritime Organisation (IMO) that must beapplied.

IMO have issued a circular (613) that details testing requirements for offshore

containers.

This circular, referenced in Marine Orders part 44, paragraph 11 is to be

replaced by circular 860. (Both circulars have similar wording.)

LOAD TESTING Prior to load testing, carry out Thorough Visual Inspection as detailed within

this document.

(There is no value in testing a container that has defects)4 Point Lifting Test:

Internal Load (not to be hung under container): a uniformly distributed load,such that the combined tare of the container and test load is equal to 2.5 times

the rated MGW.

The container should be lifted with its lifting set attached to all four padeyes.

2 Point Lifting Test:

Internal load (not to be hung under container): a uniformly distributed load

such that the combined tare of the container and test load is equal to 1.5 timesthe rated MGW.

The container should be lifted with slings attached to two diagonally opposite

padeyes during the test.

DOCUMENTATION

REQUIREMENTSPRIOR TO

LOAD-TESTING

The following requirements apply to any offshore container including baskets,

bottle racks, waste skips, completion baskets, workshops, stores and any other structure used to transport goods to and from offshore facilities.

Prior to any container being load tested, the testing facility is required to make

all practical effort to ensure that the container is designed for the intended

loading and service.

The equipment owner is required to provide the testing facility with either a

classification society (e.g. DNV) approval for the container or, engineeringdrawings and a full design package completed by an engineer experienced in

the design of offshore containers.




Page 100 August 1999

COMMENTARY ON

CLASSIFICATION

SOCIETY APPROVED

OFFSHORECONTAINERS

When a container with class society certification is presented to a NATA

accredited facility for inspection and/or load testing, the facility is not required

to verify the design.

The NATA accredited facility can proceed with load testing the container and issue the Certificate of Conformity on the strength of the Class SocietyCertification approval and the satisfactory load test.

The engineering drawings and design calculations detailed below are not

required to be presented to the inspection and/or testing facility for a class

society approved container.

Maintaining class society certification will provide acceptance of the container

at other locations throughout the world.

NATA ACCREDITED

FACILTY

RESPONSIBILITIES

When a container is presented to a NATA accredited facility for inspection

and testing according to APPEA requirements, the facility management must

recognise that they are playing a major role in ensuring the safety of offshore

containers.

ALLOWABLE

DEFLECTION

DURING &

SUBSEQUENT TO

LOAD TESTING

Allowable deflection limits are detailed within DNV 2.7-1 Certification notes

– Offshore Containers.

Refer to sections 3.7.1.2 7 3.7.1.3 of referenced DNV document.

COMMENTS ON

DEFLECTION

LIMITS

Where deflection exceeds the maximum allowable limit, the container should

be either, down-rated, repaired or scrapped.




August 1999 Page 101

INFORMATION TO

BE INCLUDED IN

ENGINEERING

INFORMATION

As a minimum the engineering design drawings, calculations and

specifications supplied by the container owner (when container is notclass society approved) to the inspection and/or testing facility should

include:

• Name of ualified desi n en ineer.• Name of verifying engineer (Design to be verified by an

independent engineer)

• S ecification for materials to be used in fabrication• Desi n Tare Nett & Maximum Gross Wei ht ratin• Welding specifications, consumables and weld procedures to be

used

All welding to be continuous fillet weld (except where otherwisespecified) with size of weld to be equal to the thickness of the steel

being welded or 6mm whichever is the lesser. Notes:1. The welding methods, procedures and personnel qualifications,

details, workmanship, quality and inspection should be specified to be in accordance with a recognised standard

• Material traceability requirements (Critical for padeyes and platesto which padeyes attach and important for primary structuremembers)

• NDT Inspection requirements at time of fabrication. Note:Whilst not all the following NDT work may have been carried out onan older container, the NDT on padeye welds is considered to be

critical requirement1. Wall and floor welds to have 100% visual only.

2. Padeye butt welds – 100% UT/RT (prior to load test)3. Padeye fillet welds - 100% UT/ RT (prior to load test)

4. Padeye butt & fillet welds – 100% MPI after load testRe-weld to have 20% inspection as per original (NATA to assist)

• Pade es must be ali ned to the centre of ravit of the load.• Pade es must tie into the rimar structure• Padeye hole to be 3mm or not more than 4% greater than shackle

pin diameter.

• Padeye width to be 75% (minimum) of opening of shackle pindiameter. This may require that bosses be welded to padeye plate.

• Design of lifting set to be attached.

• Details of surface preparation prior to apply surface coatings

• Details of coatings to be applied to container





SLINGS Sling sets may be chain or wire rope.

• Six sling assemblies are not allowed

• Chain used in stingers (or 5th

leg) must meet ISO 3076, or ISO 7593

standards.

SHACKLES Shackles must be:

• Grade “S” minimum

• Safety pin type with split pin fitted

• Bow shackles are preferred

CONTAINER

INSPECTIONS

Containers must receive a Thorough Visual Inspection both annually and

prior to any load testing.

• NDT Inspection of padeyes and floor support structure is to be carried out

every 3 years and prior to load testing.• All Thorough Visual Inspections and NDT inspections must be recorded

in a lifting equipment database.

THOROUGH VISUAL

& NDT INSPECTION

REQUIREMENTS

ANNUAL

REQUIREMENT

• Container is free from obvious defects, significant corrosion, impact

damage, cracks, etc.

• Under-floor support structure inspection.

• Place container on supports to allow full inspection of underside and

ensure adequate lighting.

• Look for extensive corrosion and/or any cracking.

• It may be necessary to sand blast corroded steel to allow full inspection.

• Suspected areas of cracking to have NDT inspections carried out.

• Steelwork that has suffered metal loss of 10% or greater throughcorrosion, is to be replaced.

Note: This may require UT checks to quantify metal loss.

• Complete structure to be examined for corrosion, cracking, and impact

damage. Particular attention is to be given to inspection of lifting points,

under-side members and corner post assemblies.

• Visually inspect all welds for defects.

• NDT all welds in padeye area. (3 yearly) NATA to advise type of NDT

• NDT a minimum of three each, selected under-floor structural welds

• Inspect for signs of mechanical damage.

• Doors, frames, seals, hinges, locks should be examined and functionally

checked to ensure satisfactory operation without undue force.

• Check floor is substantially flat with no signs of damage or other indications that may indicate overloading. Any internal floor damage may

indicate underside damage- re-check.

• Marking Plates should be as per requirements of this document.





TESTING OF

WORKSHOP

CONTAINERS,

LOGGING UNITSETC.

In the past, it has proven most difficult (if not impossible) to fit the required

test weights into containers that have work benches, shelving etc.

It is also impossible to fit weights into many logging units and other container

style cabins that either are full of specialised equipment used by servicecompanies or, only have personnel access doors.

In the case of these units APPEA has considered several options & other

interested parties have put forward options for ensuring on-going integrity.

Hanging weights under the container does little to verify the integrity and the

weights can generally only be suspended from the strongest points. This does

nothing for ensuring integrity of lesser structural members.

APPEA therefore proposes that more stringent inspection requirements apply

to these units in lieu of any load testing.

6 YEARLYINSPECTION OF

WORKSHOP

CONTAINERS,

LOGGING UNITS

ETC.

Where test weights cannot be evenly distributed across the floor area of anycontainer, logging unit etc. the following inspection methods shall be used to

ensure the on-going integrity of the equipment.

These requirements shall be additional to the ANNUAL INSPECTION

requirements as detailed on page 9

Note: This method of integrity assurance will be in lieu of load testing and will

only be carried out by NATA accredited NDT inspection facilities.

• Place container on racks to allow full underside inspection.

Note: Do NOT walk underneath containers suspended by forklift or cranes.

• Abrasive blast 25% of under-floor welds.

• Carry out MPI on all welds cleaned by blasting

• If any cracking of welds or structural members is identified, abrasive blast

a further 25% and test as described above.

• Where continued cracking is found in the additional welds cleaned that

have been cleaned for inspection, the underside should be completely

abrasive cleaned and all welds inspected by MPI method.

• Carry out UT testing of 50% of under-side structural members. Note: If any metal loss of > 10% is detected, the remaining structural

members shall also be UT checked for metal loss.

• Carry out repairs as required using approved welding procedures,

qualified welders and trace-able materials equivalent to the original

structure members as detailed on the engineering drawings.

• Carry out MPI on all weld repairs and rectify any faults detected.

• Re-coat underside of container with a suitable coating for the offshore

environment.• NATA endorsed facility shall provide the equipment owner with a “stick

diagram” of the container underside. The diagram shall identify members

and joints inspected.

• The equipment owner should ensure that all QA documents relating to

repairs carried out are complied and retained on file for future reference.

Note: Whilst the abrasive blast requirements may, at first seem to be quite

extensive, it will, in most cases be advantageous as many containers will

require re-application of coatings (particularly underneath) at the end of 6years and this work will fit well with that requirement.





VISUAL INSPECTOR

KNOWLEDGE

REQUIREMENTS

The inspector must have, as a minimum, a knowledge and adequate practicalexperience of:

• The statutory requirements relating to containers.

• The provisions of DNV 2.7-1

• The various types of containers in service.

• The correct methods of slinging and handling the containers.• The loads, stresses and strains affecting containers when handled under

adverse offshore conditions.

• The methods of testing containers as detailed in Maritime Safety.

Committee circular 860 or, DNV2.7-1 Offshore Container, Certification

Notes.

• Defects likely to be found in containers and acceptable levels of wear,distortion and deterioration in relation to safety in use.

• Welding methods and procedures and qualification of welders.

• The various methods of non-destructive examination (NDE) and a good

understanding of how they work and their limitations

• Techniques for measuring container to ensure distortion has not occurred

during service or load testing.

Offshore Container Identification Plate

OFFSHORE CONTAINER

Name of Manufacturer Month/year of Manufacture

Manufacturers Serial No.

Maximum Gross Weight Kg at deg sling angle

Tare Weight Kg

Payload Container Kg Intermediate Deck Kg

Certificate of Conformity No.

Design Temperature Degrees C

IDENTIFICATION

PLATE MATERIAL &

SIZE

REQUIREMENTS

• Plate to be of stainless steel, approximately 1 .5 mm thick


• 215 mm overall width• 150 mm overall height







Offshore Container Inspection Data Plate

INSPECTION DATA-OFFSHORE CONTAINER

Container No.Maximum Gross Weight (wt) Kg at deg, Sling angleTare Weight KgPayload - Container Kg Mid- deck Kg (Where Applicable)

Owner:Tel. No. +

DATE: DATE: DATE:

TEST TYPE: TEST TYPE: TEST TYPE:

TESTED BY: TESTED BY: TESTED BY:

DATE: DATE:

TEST TYPE: TEST TYPE:

TESTED BY:

DATE:

TEST TYPE:

TESTED BY:TESTED BY:

DATE: DATE: DATE:



DATE:

TEST TYPE:

DATE:

TEST TYPE:

TESTED BY:

DATE:

TEST TYPE:

TESTED BY: TESTED BY:

DATE: DATE: DATE:



INSPECTION DATA

PLATE MATERIAL &

SIZE

REQUIREMENTS

• Plate to be of stainless steel, approximately 1 .5 mm thick


• 215 mm overall width

• 250 mm overall height (approx.)







CERTIFICATE OF

CONFORMITY

At the completion of inspection, testing and marking compliance work the

NATA endorsed Certificate of Conformity (developed by APPEA in

conjunction with NATA) will be issued by a NATA accredited facility

In signing and approving the issue of a Certificate of Conformity the NATAaccredited facility will be advising the owners, users & transporters of the

container that the unit is “fit for intended service”.

Where doubt exists, the NATA facility should seek clarification from a

registered structural engineer, who is experienced in container design.

The Certificate of Conformity will remain current for the life of the container

provided no structural alterations are made.Any structural alterations will require the container to be re-assessed and a

new Certificate of Conformity to be issued.

ONGOINGINSPECTION & TEST

REPORTS

Ongoing, in-service reports will include the following as appropriate:• Visual Inspection Reports

• Load Test Reports

• Non Destructive Testing Reports




OK No

• Engineering drawings have been reviewed by either:

• A Classification Society (e.g. DNV, ABS, Lloyds etc.)

• An independent Qualified Engineer

• NATA accredited facilities qualified engineer.

• Drawings meet the requirements detailed within this

document.

• Container was placed on supports and a full underside

inspection carried out.

• Container has no significant corrosion and/or structural fault

affecting integrity

• Container floor is in sound condition

• Engineering drawings and structural analysis support anymodifications.

• Padeyes are fitted to the container

• Padeyes have engineering design drawings available

• Padeye design complies with the requirements of this

document.

• Container has been de-rated as per requirements of this

document

• Container has been load tested as per requirements of this

document

•

• There is no permanent distortion of the container followingload testing (Refer to DNV 2.7-1, section 37.1.2 & 3.7.1.3)

• Forklift pockets marking is as per the requirements of this

document.

• No grade T chain is used in 5th

leg of a 5 leg assembly where

is there is no redundancy

REQUIREMENTS TO

BE MET PRIOR TO

ISSUING A

“CERTIFICATE of CONFORMITY”

• NDT of padeye welds, structural member welds and floor

support structure has not revealed any cracking (or repairs

have been effected)

Documents

APPEA Lifitng and Rigging Guidelines