TAÄP HÔÏP CAÙC QUI TRÌNH THÖÛ NGHIEÄM TAÛI TROÏNG CHO

Microsoft Word - QT41-1.2 _6-2021_ T?p h?p QTTN t?i tr?ng cho phuong ti?n, d?ng c? mang t?i b? sung.docB LAO NG THNG BINH VÀ XÃ HI MINISTRY OF LABOR, INVALID AND SOCIAL AFFAIRS
TRUNG TAÂM KIEÅM ÑÒNH KYÕ THUAÄT AN TOAØN KHU VÖÏC 2 CENTER OF INDUSTRIAL SAFETY REGISTRATION ZONE 2
(CISR)
TAÄP HÔÏP CAÙC QUI TRÌNH THÖÛ NGHIEÄM TAÛI TROÏNG CHO PHÖÔNG TIEÄN, DUÏNG CUÏ MANG TAÛI BOÅ SUNG
PROCEDURES FOR LIFTING EQUIPMENT LOAD TESTING
Qui trình soá (Procedure No.): QT 41
Baûn soá (Copy No.):
QT41 – Version 1.2(6/2021) 2/55 ® Copyright of Center of Industrial Safety Registration zone 2. No Unauthorized Copying of Any Part of This Document
CONTENTS
1. Purpose 4
2. Scope 4
6. Testing Equipments 8
PART 2 : TESTING PROCEDURE
QT 41 .2 – Load testing Procedure for Wirerope Slings 15
QT 41.3 – Load testing Procedure for Chain slings 18
QT 41. 4 – Load testing Procedure for shackles 22
QT 41.5 – Load testing Procedure for hooks 24
QT 41.6 – Load testing Procedure for Links, Master Links 26
QT 41.7 – Load testing Procedure for Lifting Clamp 28
QT 41.8 – Load testing Procedure for Hammer Locks 30
QT 41.9 – Load testing Procedure for Swivel hoist Ring/Eye bolts 32
QT 41.10 – Load testing Procedure for Eye bolts/Eye Nuts 34
QT 41.11 – Load testing Procedure for TurnBuckles 36
QT 41.12 – Load testing Procedure for Sheave blocks 38
QT 41.13 – Load testing Procedure for Personal Lifting platform/suspended 41
Basket
QT 41.15 – Load testing Procedure for Manually Operated Hoists 46
QT 41.16 – Load testing Procedure for Electrical/air powered Hoists 49
QT 41.17 – Load testing Procedure for Fibre man made slings 51
QT 41.18 – Load testing Procedure for Bracket (Padeye, lifting Lug) 54
APPENDIX 1: Guide for calculation of test load/test force.
1. PURPOSE
This document provides criteria, procedures and guides to be used when carry out the proof load testing for lifting equipments. Following the criteria and procedures contained herein will enable competent personnel to perform the proof load test and assess the testing result in appropriate method.
2. SCOPE
This document specified procedure and requirements for the proof load testing of lifting equipments used on offshore facilities, onshore loading facilities and supply base. Lifting equipment herein are classified as follow:
LIFTING EQUIPMENTS
Closed freight containers Workshops
Baskets Personnel Baskets Gas cylinder racks Spreader frames Equipment skids
Long stock container Modules
subsea manifolds, Christmas trees & subsea valves
Lifting points and supporting members of machinery
(skids, valves etc)
Chain Slings Flat synthetic webbing slings
Polyester round slings Shackles
a) The person, who carried out the load testing for lifting equipment shall be qualified in accordance with CISR’s training program for inspection/examination/testing for lifting equipment and have the adequate certificate, in valid.
b) The persons, who carried out the load testing shall be ensured all safety conditions before and in all testing process.
4. REFERENCES BS EN ISO 10855-1:2018
BS EN ISO 10855-2:2018
Offshore containers and associated lifting sets – Part1: Offshore container – Design, Manufacture and marking. Offshore containers and associated lifting sets – Part1: Offshore container – Design, Manufacture and marking.
BS EN ISO 10855-3:2018 Offshore containers and associated lifting sets – Part 3: Periodic inspection, examination, and testing.
DNV standard No.2.7-1 Standard for Certification No.2.7-1
EN 970 Non-destructive examination of Fusion welds – Visual examination.
EN 1290 Non-destructive examination of welds – Magnetic particle examination of welds
EN 571-4 Non- destructive testing-Penetration testing-Part 1: General principles.
EN ISO 5817a:2003 Welding-Fusion-welded joints in steel, nickel, titanium, and their alloys-quality level for imperfections
EN 1291 Non-destructive examination of welds – Magnetic particle testing of welds-Acceptance levels
EN 1289 Non-destructive examination of welds – Penetrant testing of welds-Acceptance levels
TCVN 4244:2005 Vietnamese lifting appliance safety standard
BS EN 13414-3:2003 Wire rope slings-safety
ASME B30.9 Slings
BS EN 818:1996 Shot link chain for lifting purposes
BS EN 13889: 2003 Forged steel shackles for general lifting purposes
BS EN 3551 Alloy steel shackle
BSEN 1677-3,5 components for slings -Safety, Forged steel self- locking hooks
BSEN 13155 Cranes – Safety-Non fixed load lifting attachments
BSEN 1677-4 Components for slings – Link grade 8
ASME B30.20 Below the hook lifting devices
BS 4278 Eyebolt for lifting purpose
BS MA 47 Ships’ cargo blocks
BSEN 14502-1 Suspended basket
BSEN 13001 Crane safety - General design. General principles and requirements
ASME B30.1 Lifting Jack
EN 1494-2000 Mobile or movable jacks and associated lifting equipment
ASME B30.21 Manual operated lever chain hoist
BS EN 13157-2004 Cranes, Safety. Hand powered lifting equipment
ASME B30.11 Monorail Systems and Underhung Cranes
ASME B30.16 Overhead Hoists (Underhung)
BS EN 1492-1 Textile slings- Safety, flat woven webbing slings
BS EN1492-2 Textile slings – Safety round slings, made of man-made fibre for general purpose use
NSL communicating Safety
The International Rigging and lifting handbook
DOE-STD-1090 Hoist and rigging standard of the U.S. Department of Energy
AS 1353.1-1997 Flat synthetic-webbing slings 5. TERMS, DEFINITIONS, ABBREVIATIONS
This document used the definitions, terms and abbreviations mentioned in the applied references and:
- Offshore container (OC): portable unit for repeated use in the transport of goods or equipment handled in open seas to, from, and between fixed and/or floating installations and ships.
- R, Rating: the maximum gross mass of the container including permanent equipment and its cargo, in kg; but excluding the weight of lifting set.
- T, Tare mass: the mass of an empty container including permanent equipment but excluding cargo and lifting set, in kg.
- P, payload: the maximum permissible mass of cargo which may be safety transported by the container, in kg. P= R-T
- S, lifting set mass: mass of the lifting set, in kg.
- Lifted Equipment: Equipment that the rigging connects to. In the case of machinery, valves, etc… with attached pad eyes, 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 materials handling equipment.
- 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 pad eyes.
- NDT: Non-Destructive testing, including magnetic particle, penetrant testing, ultrasonic testing.
- MPI/MT: Magnetic particle testing.
- PT: Penetrant testing.
- 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). Safe working load of a crane is the maximum mass which is permitted to be safely handled by the crane.
- Working load limit (WLL): The maximum mass or force which a product is authorized to support in general service when the pull is applied in-line, unless noted otherwise, with respect to the center line of the product. Working load limit (WLL) should replace safe working load (SWL) in describing the capacity of items such as hooks, slings, and shackles etc.
- Qualified Inspector: One whose competence is recognized by the responsible manager and whose qualification to perform specific inspection activities has been determined, verified, and attested to in writing
- Visual inspection: inspection of the characteristics of a product and determination of its conformity with specified requirements where applicable and based on professional judgement where general requirements apply. Visual inspection may include visual and dimensional.
- Proof load test: The load test to be carried out with the test load required by the code or standard for the specific equipment.
- Shall: Indicates a mandatory requirement
- Should: Indicates a recommended requirement
6. TESTING EQUIPMENTS
The equipment, which supported for the inspection/testing include: 6.1. Lifting appliances, lifting gears:
Lifting equipment and lifting gears served to the inspection/testing include but not limit the belows: lifting appliances (cranes, gantry crane, overhead crane...), special test rigs; wire rope sling, chain sling, web sling; Shackle, Ring, hooks...; the equipment shall be satisfied requirements as follows: - All equipment is in good working situation, safety. - The structure, capacity and dimension are suitable for the objects to be
inspected/tested (e.g., the minimum capacity shall be at least 125% requirement capacity/test load for testing).
- The lifting appliances, lifting gear must have the valid inspection/testing certificate.
6.2. Load cell, Dynamometer: - Equipment used to measure weight/test force as scales, dynamometers or load cells.
That equipment is in good working situation, safety; have the valid calibrated certificate.
- The range/capacity of the load cell ensure that the requirement’s test weight/force is within load cell capacity/range and the maximum accuracy of calibrated load cell is 2%.
6.3. Test load (Test masses, test block): - The appropriate means of application test load/test mass are:
o Calibrated test blocks. o Water bags. o Sandbags. o Free weights. o A suitable test Rig.
- Where used, the test block with the identified weight, the test blocks shall be calibrated annually in accordance with acceptable international/nation standard, the measured mass, in kilograms, of each block shall be legibly and durably marked on each block.
7. TESTING PLACE, WEATHER
- The testing site shall have sufficient space to carried out the inspection/testing; hardness, flatness; ensure the safety distance to the electrical power line is in conformity with the local/nation code; should be limited/segregated from another working site.
- When carried out the inspection/testing out site, the weather must be in good condition, no rain and wind speed is not exceeding level 4 in the beaufort scale (<= 8 m/s).
PROCEDURE No: QT 41.1
A- SCOPE
This procedure provides general guidelines for competent person performing the load testing for container, cargo baskets, etc… with maximum gross mass not exceeded 25,000kg, intended for repeated use, include types:
b) Offshore freight containers like as: - General cargo container: Closed container with doors - Cargo basket: Open top container for general or special cargo - Tank container: container for the transport of dangerous or non-dangerous fluids. - Bulk container: container for the transport of solid in bulk. - Special container: container for the transport of special cargo, e.g., garbage containers, equipment boxes, gas cylinder racks.
c) Offshore service containers like as: Offshore Container built and equipped for the special service task, usually as a temporary installation, e.g., laboratories, workshops, stores, power plant.
d) Waste skip: open or closed offshore container use for storage and removal of waste.
Note: This procedure also applies for some units incorporates permanently installed equipment for lifting and handing and may include equipment for filling, emptying, cooling, heating, etc…
The guidance and recommendation will meet the requirements of:
- BS EN ISO 10855:2018 Parts 1,2,3: Offshore containers and it associated lifting sets.
- DNV CN 2.7-1: DNV standard for certification offshore containers
B- LOAD TESTING
I- Technical Requirements prior to testing:
The inspector, who carried out the load testing, shall clearly determine the significant specification of the container included tare mass(T), rating(R) by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check.
II- Lifting Test:
- The inspector/tester should be selected the sets of lifting appliances, load cell, test weight and lifting gear suitable for specified testing requirements.
- The operator shall be set up the lifting appliance (or suitable test rig) correctly, safety and suitable for specified testing requirements and put the container/associated lifting sets on the right test position.
- The operator/rigger shall be fitted the slings and other lifting sets into all pad eyes of container as its normal operation condition. The master link of sling connecting to the hooks of lifting appliance by means of load cell’s shackle, all fitting shall be corrected and secured. Lift the container by means of hoist of lifting appliance (or hoist of test rig) to check the weight of empty container and its associated lifting set through load cell (check and determine T).
* Note 1: where the lifting set intended for use with the container is used for the lifting test, care should be taken to ensure that no overloading, distortion, or deformation is included in the lifting set. Should the lifting set normally fitted to the container be used for the lifting test, it should be visually inspected after the load test.
* Note 2: The container shall be lifted by a lifting set with an angle to the vertical equal to the design angle.
III- Calculation and arrangement of the additional test load/test mass:
- The inspector shall be calculated the weight of added test block so that the total weights of empty container(T) and test blocks (Pt, testing weight) equal to 2,5 (for all points testing- Meet requirement of Item 7.3.3 BSEN ISO 10855-1 and item 7.1 BSEN ISO 10855-1) or 1,5 (for two points testing- Meet requirement of Item 7.3.3 BSEN ISO 10855-1) multiplied by the rating of maximum gross mass (R):
+ For all points lifting test: T+ Pt = 2,5x R = 2,5 (P+T)
+ For two points lifting test: T+ Pt = 1,5x R = 1,5 (P+T)
- The test mass/test load shall normally be evenly distributed inside the container. If it is not possible to place all test load inside the container, some of it may be placed outside or under the container provided this gives a loading on the structure similar to the distribution of the container loading in operation condition. If the container has an additional cargo deck, the test mass/test load shall be evenly divided between the additional deck and the floor. To be carried out the test as well as with the whole test load/test mass on the floor.
Guidence Note: If it is not possible to place the additional free test load outside or under the container, the inspector can be permited to use the suitable tool such as fibre slings to secure the bottom corners of container to the fixed deadweight to get the required test load/force provided the test force shall be controled by appropriate means/ methods to keep the test force will not exceed to the required test load.
III.1- All point lifting test:
- Used the hoist of lifting appliance to slowly and carefully lift all the container included test load/test mass in such a way that no significant acceleration forces occur, lifted clear of ground. Checked by means of load cell to ensure that the test force/test weight is adequate with the requirement. It shall be held at least 5 minutes before measurements are taken.
- Carefully observed to detect any failure and deformation, broken, cracks., which will be appeared in all test process.
- The Inspector shall be measured, recorded all failure, deflection appeared on the testing process (If any, with eyes and by means of suitable measurement equipment as rule, theodolite...).
- After that testing, released all tensioning in testing system and disconnect all lifting gears from the container. Inspector shall thoroughly carry out the visual inspection for all the main structure, pad eyes… for the deformation, broken, cracks, mechanical damages....
- The welds of padeyes shall be examined by appropriate NDE methods (MT/PT) in compliance with requiremment of item 8- BS EN ISO 10855-3(for periodic test) or item 8.2.3- BS EN ISO 10855-1(for production type test).
- The Eddy current testing (ET) can be accepted in the periodic testing provided it meets the requirement of item 8.3 BS EN ISO 10855-3.
Assessment:
- Except the special case as requirements of client, the testing result is reputed to be satisfactory, where:
o No permanent deformation, cracks or other mechanical damages in the Primary structure and welds were detected by means of inspection/examination after testing.
III.2 – Two-point lifting test (Diagonal lifting test) - An offshore container with four pad eyes shall also be lifted from only two pad
eyes, situated diagonally opposite each other, with a total mass of 1.5 x R. If the container is un-symmetrical, two diagonal lifting tests will be carried out with each pair of pad eyes.
- The container shall be subjected the test load/test force at least 5 minutes before measurements are taken.
- Carefully observed to detect any failure and deformation, broken, cracks., which will be appeared in all test process.
- The inspector shall be measured, recorded all failure, deflection appeared on the testing process (If any, with eyes and by means of suitable measurement equipment as rule, theodolite...).
- After that testing, released all tensioning in testing system and disconnect all lifting gears from the container. Inspector shall thoroughly carry out the visual inspection for all the main structure, pad eyes… for the deformation, broken, cracks, mechanical damages....
- The welds of padeyes shall be examined by appropriate NDE methods (MT/PT) in compliance with requiremment of item 8.2.3- BS EN ISO 10855-1(for production type test).
Assessment:
Except the special case as requirements of client, the testing result is reputed to be satisfactory, where:
o No permanent deformation, cracks or other mechanical damages in the Primary structure and welds were detected by means of inspection/examination after testing.
* Guidance note: Elastic deformations during lifting should also be observed. The Inspector should ensure that elastic deformations are acceptable.
IV- Report the result of testing:
- The inspector shall be completed and reported the result of testing in accordance with the form M16.1.1- QT 16
Example of offshore container:
PROCEDURE No: QT 41.2 LOAD TESTING PROCEDURE FOR WIREROPE SLING
A- SCOPE
This procedure provides general guidelines for competent person performing the
load testing of wire rope, wire rope sling for general lifting service with diameter of slings are between 8mm to 60mm.
- BS EN 13414-1,2,3: 2003: Wire rope slings-safety
- ASME B30.9: Slings
B- LOAD TESTING
I- Technical Requirements prior to inspection:
The inspector, who carried out the load testing, shall clearly determine the significant specification of the slings by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
* Formation of sling
The sling shall comprise two, three or four legs of the types specified as below:
Some typical sling assemblies are illustrated in Figure 1 for two-three- and four-leg slings. The lower terminal fittings can be any of those shown in Table 2.
II- Proof load test
Personnel in charge of testing shall decide, with his/her competence and test facilities, the method of proof load testing. He/she can choose either A or B as test method of the mentioned below:
Method A: The wire rope sling set shall be lifted/pulled one (1) time with all legs. based on the WLL (in T) of sling set, therefore test load shall be: 2 x WLL set of slings (for mechanical splice and endless sling); and test load shall be: 1.25 x WLL set of slings (for hand tucked slings). Refer to the chapter 9-2, section 9-2.6.2 of ASME B30.9 or DOE-STD- 1090-2004 item 11.3.2.2 for detail.
Note: The angle of legs will be approximately 450 to vertical.
Method B: The wire rope sling set shall be tested by single leg using tension test bed, load test rig or lifting appliance with appropriate test blocks.
- The proof load for mechanical splice single leg slings and endless slings shall be two (2) times the vertical rated load.
- The proof load for multiple leg bridle slings shall be applied to the individual legs and the proof test load shall be either (Only for the sling which used mechanical splice):
+ for 3,4- legs sling: 2 x (WLL All leg s sling)/ KL=2,1.
+ for 2-legs sling: 2 x (WLL All leg s sling)/ KL=1,4
Note: KL is the leg factor of wire rope sling, refer to table 3- BS EN 13414:2003 for detail.
- Any master link to which multiple leg slings are connected shall be proof loaded to two times the force applied by the combined legs.
The wire rope sling shall be carefully loaded in such a way that no significant acceleration forces occur. It shall be held for at least 5 min before reading are taken.
After load test:
After completion of the proof force/load test, and the removal of the force/load, the wire rope or wire rope sling shall be throughout checked for any damage and defect.
- The test shall be considered satisfactory if no cracks, wire break, permanent deformation or damage that would adversely affect the function or safety of the wire rope or wire rope sling is visible.
III- Report the result of testing:
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M 16.2.1- QT 16
PROCEDURE No: QT 41.3 LOAD TESTING PROCEDURE FOR CHAIN SLINGS
A- SCOPE
This procedure provides general guidelines for competent person performing the load testing of chain sling for general lifting service with the range of nominal sizes of chain covered by EN 818-2,3 is from 4mm to 45mm...
This guidance and recommendation will meet the requirements of:
- BS EN ISO 10855:2018 Part 3: Offshore containers and it associated lifting sets.
- BS EN 818: 1996: shot link chain for lifting purposes
- ASME B30.9 Chapter 9.1: Alloys steel chain Slings
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the chain sling included tare mass(T), rating(R) by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
NOTE: Some typical sling assemblies are illustrated in Figure 1 for two-three- and four-leg slings.
III- Proof load test
Proof test will be carried out by using tension testing machine or lifting appliance with free test weight. Proof load test shall be applied on chain slings at the following circumstance: prior to use, all new, altered, modified, repaired, or at periodic inspection.
Personnel in charge of testing shall decide, with his/her competence and test facilities, the method of proof load testing as below requirement:
- The chain sling set shall be tested by tension test bed, load test rig or lifting appliance with appropriate test blocks.
- The proof load for single leg sling shall be two (F=2,0) times the vertical rated load.
- The proof load for multiple leg slings shall be applied to the individual legs and the proof test load shall be either:
+ for 3,4- legs sling: 2 x (WLL All leg s sling)/2,1 (Test factor F=2)
+ for 2-legs sling: 2 x (WLL All leg s sling)/1,4 (Test factor F=2)
- Any master link to which multiple leg slings are connected shall be proof loaded to two times the force applied by the combined legs (Test factor F=2).
- For offshore container chain lifting set in accondance with BS EN ISO 10855, the proof test factor is: F=2,5.
The test load/test force with maximum accuracy +/- 2%, shall be applied to sling or legs without shock. The load shall be applied for a minimum of 5 minutes before measurements are taken.
Note: The inspector should consider carry out the test for other parts of chain sling if needed or required, refer to the corresponded inspection procedure in this document for detail.
C. After proof load test:
After completion of the proof force test and removal of the force, the chain sling shall be throughoutly inspected and examined by visual inspection/ appropriate MT/PT methods (if need) for any damage and defect.
- The test shall be considered satisfactory if no cracks, breaks, permanent deformation, or damage that would adversely affect the function or safety of the chain sling is visible.
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M 16.3.1-QT 16
PROCEDURE No: QT 41.4 LOAD TESTING PROCEDURE FOR SHACKLES
A- SCOPE
This procedure provides general guidelines for competent person performing the load testing of forged steel shackle for general lifting service.
- BS EN 13889: 2003 Forged steel shackles for general lifting purposes.
- ASME B30.26-2004: Rigging Hardware
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly know the specifications of the shackles by means of review manufacture documents, last inspection/testing report or re- calculated to check.
* Typical Shackles
Figure 1 — dee shackle; bow shackle
Key: 1 Crown ; 2 Body ; 3 Example of screwed pin with eye and collar – type W; 4 Eye ; 5 Bolt type pin with hexagon head, hexagon nut and split cotter pin – type X.
II- Proof load test
Proof test will be carried out by using tension testing machine or lifting appliance with free test weight. Each shackle, shall be subject to a proof load test at the center of the pin equal to Test load as below:
Applied Standard Working load limit (WLL)
Test Load Applied
TCVN 4244:2005 >25T 1,22xWLL +20T
BS EN 13889: 2003 ≤ 25T 2 x WLL
ASME B30.26-2004 ≤136 T 2xWLL
ASME B30.26-2004 >136 T 1,33xWLL
The shackle shall hold the test load for a minimum 5 minutes without showing permanent deformation or breaking.
After load test, the shackle shall be thoroughly visual checked/examined to ensure that are free from visible flaw, deformation or others defect.
- The inspector shall be completed and reported the result of testing in accordance with the form M16.4.1-QT16.
A- SCOPE
This procedure provides general guidelines for competent person performing load testing services for lifting hooks complying with standard and code:
+ BSEN 1677-3,5: components for slings , Forged steel lifting hook with latch and eye;
+ BSEN 13155, Cranes – Safety-Non fixed load lifting attachments;
+ ASME B30.10- Hooks.
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the hooks, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
II- Proof load test
Proof test will be carried out by using tension testing machine or lifting appliance with free test weight. Each hook, shall be subject to a proof load test at the centre line equal to Test load as below:
Test Load Applied
>25T 1,22xWLL +20T
ASME B30.10 WLL ≤50T 2 x WLL
The shackle shall hold the test load for a minimum 5 minutes without showing permanent deformation or breaking.
After load test, the shackle shall be thoroughly visual checked/examined to ensure that are free from visible flaw, deformation or other defect.
- The inspector shall be completed and reported the result of testing in accordance with the form M16.5.1-QT 16
LOAD TESTING PROCEDURE FOR
A- SCOPE
This procedure provides general guidelines for competent person performing load testing for link and master link complying with BSEN 1677-4 Components for slings – Links grade 8; DOE-STD-1090-2001 Hoisting and Rigging.
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the links, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical links, link assambly types :
Master link assembly Master link Connecting link
Proof test will be carried out by using tension testing machine or lifting appliance with free test weight. Each link, shall be subject to a proof load test at the centre line equal to Test load as below:
Test Load Applied
>25T 1,22xWLL +20T
The test force/load shall be held for 5 minutes.
After removal of the force, there shall be no visible defect such as break, crack and deformation, and the dimensions shall be within the tolerances specified on the manufacturer’s document.
V- Report the result of testing:
- The inspector shall be completed and reported the result of testing in accordance with the form M 16.6.1-QT 16
A- SCOPE
This part provides general guidelines for competent person performing beam clamp, plate clamp load testing services according to requirement of client. The guidance and recommendation will meet the requirements of:
- Manufacturer Recommendation
- The International Rigging and lifting hand book (NSL communicating Safety).
- BSEN 13155 – Non-fixed load fitting attachments
- ASME B30.20- Below the hook lifting devices
- DOE-STD-1090-2004 chapter 14– Below the hook lifting devices
- TCVN 4244:2005: Vietnamese lifting appliance safety standard.
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the clamp, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical clamp types :
II- Proof load test
Each clamp, after the throughout check, shall be subject to a proof load test. If no specific requirement of manufacturer technical or clien’t requirement, As follow TCVN 4244:2005 standard, appendix 16, the Proof test Load/force (PL) shall be:
* For horizontal and vertical clamp, where SWL ≤ 25tons , PL=2x SWL tons ; SWL > 25tons , PL=1,22x SWL+ 20 (tons).
* For beam clamp : PL = 1,5x SWL
The beam/plate clamp shall be carefully loaded in such a way that no significant acceleration forces occur. It shall be held for 5 min before reading taken.
* After load test
After load test, the clamp shall be throughout checked for any damage and defect.
- The test shall be considered satisfactory if no cracks, permanent deformation or damage that would adversely affect the function or safety of clamps is visible.
- If, satisfactory, the clamp shall be stamped the date of inspection on data plate
of the clamp and a report/ certificate shall be issued by the inspector
III- Report the result of inspection/testing:
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M16.7.1-QT 16
This part provides general guidelines for competent person performing load testing services for the hammer locks.
B- LOAD TESTING
I- Technical Requirements prior to inspection: The inspector, who carried out the load testing, shall clearly determine the significant specification of the hammer lock, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical hammer lock types :
II- Proof load test
The hammer locks shall be load tested together with chain sling, hooks, links, component in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before reading taken.
The proof load of hammer lock shall be the same with the component that it has been attached to or corresponding with the proof load of the sling leg. . If no specific requirement of manufacturer technical or client’s requirement, the Proof test Load/force (PL) shall be (TCVN 4244:2005- appendix 11):
+ Where SWL ≤ 25tons, PL= 2x SWL tons; + Where SWL > 25tons, PL= 1,22x SWL+ 20 (tons).
* After load test
After load test, the hammer lock shall be throughout checked for any damage and defect. The test shall be considered satisfactory if no cracks, permanent deformation or damage that would adversely affect the function or safety of hammer lock is visible. If, satisfactory, the hammer lock shall be stamped the date of inspection on data plate of the hammer lock/the sling that it was attached and a report/ certificate shall be issued by the inspector.
- The inspector shall be completed and reported the result of testing in accordance with the form M16.8.1-QT 16 .
PROCEDURE No: QT 16-DNV.9
HOIST RINGS/ SWIVEL EYEBOLTS
This part provides general guidelines for competent person performing swivel hoist rings/swivel eyebolt load testing services.
- TCVN 4244:2005, appendix 11: Vietnamese lifting appliance safety standard.
- DOE-STD-1090 Hoisting and Rigging
The inspector, who carried out the load testing, shall clearly determine the significant specification of the hoist rings/swivel eyebolt, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical swivel hoist rings/swivel eyebolt:
II- Proof load test
The Swivel hoist rings shall be load tested in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before reading taken.
If no specific requirement of manufacturer technical or client’s requirement, the
Proof test Load/force (PL) shall be (TCVN 4244:2005- appendix 14): + where WLL ≤ 25tons , PL = 2 x WLL tons; + where WLL > 25tons , PL = 1,22 x WLL+ 20 (tons).
Test weights shall be accurate to with -5 percent, +0 percent of stipulated values.
If proof testing cannot be verified, the swivel hoist rings shall be proof tested before being used to make a critical lift.
After load test, the Swivel hoist rings shall be throughout checked for any damage and defect. The test shall be considered satisfactory if no cracks, permanent deformation or damage that would adversely affect the function or safety of Swivel hoist rings is visible. If, satisfactory, the Swivel hoist rings shall be stamped the date of inspection on data plate and a report/ certificate shall be issued by the inspector.
PROCEDURE No: QT 16-DNV.10
This part provides general guidelines for competent person performing eyebolt load testing services according requirement of client.
- BS 4278:1984 : Eyebolt for lifting purpose
- DOE-STD-1090 Hoisting and Rigging
The inspector, who carried out the load testing, shall clearly determine the significant specification of the Eye bolt/nuts, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical Eye bolt/nuts
II- Proof load test
The eye bolt shall be load tested in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before reading taken.
If no specific requirement of manufacturer technical or clien’t requirement, the Proof test Load/force (PL) shall be (TCVN 4244:2005- appendix 14):
+ where WLL ≤ 25tons , PL= 2x WLL tons ; + where WLL > 25tons , PL= 1,22x WLL+ 20 (tons).
Test weights shall be accurate to with -5 percent, +0 percent of stipulated values.
If proof testing cannot be verified, the eye bolt shall be proof tested before being used to make a critical lift.
After load test, the eye bolt shall be throughout checked for any damage and defect. The test shall be considered satisfactory if no cracks, permanent deformation or damage that would adversely affect the function or safety of eye bolt is visible. If, satisfactory, the eye bolt shall be stamped the date of inspection on data plate and a report/ certificate shall be issued by the inspector.
QT41 – Version 1.2 (6/2021) 36/55 ® Copyright of Center of Industrial Safety Registration zone 2. No Unauthorized Copying of Any Part of This Document
This part provides general guidelines for competent person performing turn buckle load testing services according to requirement of client.
- DOE-STD-1090 CHAPTER 12 Rigging Accessories.
- NSL : Lifting equipment legislation matrix.
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the turnbuckle, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical turnbuckle:
II- Proof load test
The turnbuckle shall be load tested in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before reading taken.
If no specific requirement of manufacturer technical or client’s requirement, the Proof test Load/force (PL) shall be (TCVN 4244:2005- appendix 15) PL= 2x WLL
Test weights/test force shall be accurate to with -5 percent, +0 percent of stipulated values.
After load test, the turnbuckle shall be throughout checked for any damage and defect. The test shall be considered satisfactory if no cracks, permanent deformation or damage that would adversely affect the function or safety of
turnbuckle is visible.
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M16.11.1_QT 16
This part provides general guidelines for competent person performing sheave blocks load testing according to requirement of client.
- DNV Standard for certification of lifting appliance No.2.2.2
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the sheave blocks, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical sheave blocks :
The sheave blocks shall be load tested in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before reading taken. Test weights/test force shall be accurate to with -5 percent, +0 percent of stipulated values.
If no specific requirement of manufacturer technical or clien’t requirement, the Proof test Load/force (PL) shall be as requirement of DNV standard No.2.2.2 as follow:
- Single Sheave Block : PL = 4 SWL
- Multi sheaves Block :
25tonnes < SWL ≤ 160 tonnes : PL = 0,993 SWL +27tonnes
SWL > 160 tonnes : PL = 1,1 x SWL
In the case of multiple sheave blocks, the safe working load is the resultant load on the head fitting.
In the case of single sheave blocks, the resultant load on the head fitting will be twice the safe working load (SWL) marked on the block.
There should be a separate test on the becket, and its safe working load should be taken as one-fifth of the minimum breaking load of the wire rope.
The testing machine should be verified in accordance with the requirements of BS 1610, and maintained within grade B. Its full load should be not more than 10 times the proof load.
- Examination after load test:
After proof loading, all parts of the blocks should be thoroughly examined by a competent person. The shanks of the swivel head fittings and the sheaves should rotate freely by hand, and the block should be accepted only if found free from deformation, cracks, flaws, or other defects.
- The inspector shall be completed and reported the result of testing in accordance with the form M16.12.1_QT 16.
PERSONAL LIFTING PLATFORM/SUSPENDED BASKETS
This part provides general guidelines for competent person performing personal platform load testing services according to requirement of client.
- BSEN 14502-1-2005 (Suspended basket)
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the personal platform, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical personal platform:
Suspended basket longer than 2 m Suspended basket with single suspension
Suspended basket longer than 2 m Personnel Lift Platform
The personal platform with lifting accessories shall be load tested in such a way that no significant acceleration forces occur. It shall be held for 5 minutes before reading taken. Test weights/test force shall be accurate to with -5 percent, +0 percent of stipulated values with the load suitably distributed.
If no specific requirement of manufacturer technical or client’s requirement, the Proof test Load/force (PL) shall be as follow detail:
+ At least annually and at each new job site, before personnel are hoisted, the personnel platform and suspension system shall be load-tested to 150 percent of the personnel platform’s rated capacity, the load is applied at the worst position on the floor, any resulting inclination shall not exceed 20o.
+ Structural repair or modification to the platform requires load-testing to 150 percent of the rated capacity.
After proof loading, all parts of the platform with lifting accessories should be thoroughly examined by a competent person. It should be accepted only if found free from deformation, cracks, flaws, or other defects.
- The inspector shall be completed and reported the result of testing in accordance with the form M16.1.1_QT 16.
A- SCOPE
This part provides general guidelines for competent person performing the lifting beam/spreader/frame load testing services according to requirement of client.
- DNV Standard for certification of lifting appliance No.2.2.2
- BSEN 13001, Crane safety - General design. General principles and requirements.
- BSEN 13155: Crane safety- none fixed load lifting attachments
- The International Rigging & Lifting Handbook (NSL Communicating Safety)
- ASME B30.20: Below the hook lifting devices
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the lifting beam/ spreader bar/frame, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical lifting beam/ spreader bar/frame:
Load-supporting lifting devices
Friction-type pressure gripping lifting devices.
Indentation-type gripping lifting device
The lifting beam/spreader shall be load tested in such a way that no significant acceleration forces occur. It shall be held for 10 minutes before reading taken. Test weights/test force shall be accurate to with -5 percent, +0 percent of stipulated value with the load suitably distributed.
If no specific requirement of manufacturer technical or clien’t requirement, the Proof test Load/force (PL) shall be (DNV No.2.2.2):
+ where SWL ≤ 10 tonnes , PL=2x SWL tonnes ; + where 10 tonnes < SWL ≤ 160 tonnes , PL=1,04x SWL+ 9,6 tonnes.
+ where SWL > 160tonnes , PL=1,1x SWL.
After proof loading, all parts of the beam/spreader should be thoroughly examined by a competent person. It should be accepted only if found free from deformation, cracks, flaws, or other defects.
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M16.1.1- QT 16
MANUAL OPERATED CHAIN HOIST
A- SCOPE
This procedure provides general guidelines for competent person performing manual operated chain hoist (chain block and lever chai hoist, with friction brake type load- controlling mechanisms) load testing services according to requirement of client.
- ASME B30.21: Manual operated lever chain hoist
- BS EN 13157-2004: Cranes, Safety. Hand powered lifting equipment
- DOE STD 1090 -2004 chapter 8: Hoists
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the chain hoist, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical Manual operated chain hoist covered by this procedure:
Friction brake type load-controlling mechanisms of hoists.
Lever chain hoist Hand chain hoist (chain block)
III- Load Testing :
The manual operated chain hoists shall be subjected to test as follow:
III.1- Functioning test (Recommended following requirements of DOE STD 1090 - 2004 chapter 8)
- Check all functions of the hoist, including lifting and lowering without load.
- After testing unloaded, apply a load of at least 50 lb (23 kg) with hand chain hoist or 100lb (46kg) with lever chain hoists multiplied by the number of load-supporting parts of load chain to the hoist to check proper load control.
III.2- Static load test (according to EN 13157:2004 +A 1:2009)
- The test load/test force is 150% rated capacity ( 1,5 SWL) if the SWL less than 20 tonnes and 125% rated capacity ( 1,25 SWL) if the SWL equal or greater 20tonnes.
- The chain hoists shall be capable of holding the test load/test force within 10minutes. Observe the test process.
- After this test, the chain hoist and it parts should be accepted only if found free from permanent deformations, cracks, or other defects.
III.3- Dynamic load test
- The test load/test force is 110% rated capacity ( 1,1 SWL)
- Lifting and lowering this load for 3 cycles. The chain hoist shall be capable of lifting and lowering this load normally. The load brake control shall stop and hold the load when the lever force (hand chain) is removed and the lever stroke is completed.
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M16.15.1-QT 16
ELECTRIC/AIR POWERED CHAIN HOIST
This procedure provides general guidelines for competent person performing electric/air powered hoist (that are not permanently mounted on overhead cranes) load testing services according to requirement of client.
- EN 13157:2004+A1:2009 : Cranes - Safety - Hand powered cranes
- ASME B30.16 : Overhead Hoists (Underhung)
- DOE STD 1090 -2004 chapter 8 : Hoists
- TCVN 4244:2005 : Vietnamese lifting appliance safety standard.
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the electric/air powered hoists, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check
Typical electric/air powered hoists covered by this procedure:
electric/air powered welded chain hoists electric/air powered wire rope hoists
II- Load Testing:
The electric/air-powered hoists shall be subjected to test as follow:
III.1- Functioning test
- Check all functions of the hoist, including lifting and lowering without load.
- Check operation of brakes.
- Determine the trip-setting of limit devices by tests under no-load conditions. Conduct tests first by hand, if practical, and then under slowest speed obtainable. Test with increasing speeds up to maximum speed.
III.2- Static load test
- The chain hoists shall be capable of holding the test load/test force within 10minutes. Observe the test process.
- After this test, the hoist and it parts should be accepted only if found free from permanent deformations, cracks, or other defects.
III.3- Dynamic load test
- Lifting and lowering this load for 3 cycles. The hoist shall be capable of lifting and lowering this load normally. The load brake control shall stop and hold the load hook when controls are released; limit the speed of the load during lowering to a maximum of 120 percent of the rated lowering speed for the load being handled; stop and hold the load hook in the event of a complete power failure.
- If satisfactory, the hoist shall be hard stamped in adequate position (or data plate) with test details and a report or certificate will be issued.
- The inspector shall be completed and reported the result of testing in accordance with the form M16.16.1-QT16
load testing of man-made web sling, round sling with SWL up to 40tonnes for general lifting service.
- BS EN 1492-1, Textile slings- Safety, flat woven webbing slings;
- BS EN1492-2, Textile slings – Safety round slings, made of man-made fibre for general purpose use);
- AS 1353.1:1997 : Flat webbing
- DOE-STD-1090:2001 Hoisting and Rigging.
The inspector, who carried out the load testing, shall clearly determine the significant specification of the firble sling, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check Some typical firble sling
Webbing sling
Round sling
Proof test will be carried out by using tension testing machine or lifting appliance with free test weight. Proof load test shall be applied on slings at the following circumstance: prior to critical use, all new or periodic inspection;
Unless other requirements applies, assembled slings with fittings shall be subjected to a proof force test. The proof load are:
- Single-leg slings and endless slings : 2 x SWL
- Multiple-leg bridle slings shall be applied to the individual legs with proof test load/force:
+ for 2-legs sling : 2 x (WLL All legs sling )/1,4
+ for 3,4-legs sling : 2 x (WLL All legs sling )/2,1
- Any master link to which multiple leg slings are connected shall be proof loaded to two times the force applied by the combined legs.
The accuracy of test load/test force within - 5% to 0% of stipulated values, the test load/test force shall be applied to each section without shock. The load shall be applied for a minimum of 5 minutes before measurements are taken.
- The inspector shall be completed and reported the result of inspection/testing in accordance with the form M16.17.1-QT16
A- SCOPE
load testing for brackets as lifting point, supporting point or securing point, mounted in lifting steel structure or offshore steel platform, for suspending, supporting or securing.
The guidance and recommendation will meet the requirements of :
- DNV No. 2.2.2 : Standard for certification of Lifting Appliance
- API RD 2A : Recommended practice for planning, designing, constructing fixed offshore platforms.
- APPEA, guidelines for lifting equipment (Australia Petroleum & Exploration Association Limited).
B- LOAD TESTING
The inspector, who carried out the load testing, shall clearly determine the significant specification of the brackets, by an appropriate method, such as reviewing the technical document, last inspection/testing report or re-calculated to check III- Proof load test
When all the requirement inspections in the section II above, were assessed with satisfactory, the pad eye will be go on to the lifting test stage.
Proof test will be carried out by using hydraulic pull tester or lifting appliance with free test weight.
Unless other requirements applies, the pad eye shall be subjected to a proof force test. The proof test load for welded pad eye to Item are (According to Appendix F-DNV Standard for certification lifting appliance, 2008):
Safety Working Load (SWL) Proof test load
Up to 20 tonnes 1,25 x SWL
20 – 50 tonnes SWL + 5 tonnes
Above 50 tonnes 1,1 x SWL
The accuracy of test load/test force within + 2% of stipulated values, the test load/test force shall be applied to each section without shock. The load shall be applied for a minimum of 5 minutes before measurements and visual check are taken.
In normal case, brackets shall be periodically inspected, examined and tested annually or
before critical use.
III- Report the result of inspection/testing:
- The inspector shall be completed and reported the result of inspection/testing m
accordance with the form M 16.18.l_QT16
Typical proof load testing diagram for Brackets:
-t---hydraulic jack
Pad eye to be tested
1 Tested by using lifting appliance and free weight 2 Tested by hydraulic pull tester
QT41 – Version 1.2 (6/2021) Pages 1 ® Copyright of Center of Industrial Safety Registration zone 2. No Unauthorized Copying of Any Part of This Document
APPENDIX 1: REFERRENCE TABLE
Procedure No.
BSEN 12079; DNV 2.7-1
R ≤ 25t Lifting test with all point: 2,5 R ; Lifting test with two point: 1,5 R
QT 41.2 Load testing Procedure for Wirerope Slings
ASME B30.9 WLL 2WLL with mechanical splice & endless sling; 1,25WLL with hand tucked sling.
BSEN ISO 10855; DNV 2.7-1
WLL 2,5 WLL
QT 41.3 Load testing Procedure for Chain slings
ASME B30.9 2WLL WLL≤25T 2WLL TCVN
4244:2005 WLL>25T 1,22WLL+20T BS EN 13889 ≤ 25T 2 x WLL ASME B30.26 ≤136 T 2xWLL
QT 41.4 Load testing Procedure for shackles
ASME B30.26 >136 T 1,33xWLL WLL≤25T 2WLL TCVN
4244:2005 WLL>25T 1,22WLL+20T WLL≤50T 2WLL QT 41.5
Load testing Procedure for hooks
ASME B30.10 WLL>50T See table 10-1.7.1 of
standard ASME B30.10 WLL≤25T 2WLL TCVN
4244:2005 WLL>25T 1,22WLL+20T QT 41.6 Load testing Procedure for Links, Master Links
ASME B30.26 2WLL WLL≤25T 2WLL
QT 41.7 Load testing Procedure for Lifting Clamp
TCVN 4244:2005 WLL>25T 1,22WLL+20T
WLL≤25T 2WLL QT 41.8
Load testing Procedure for Hammer Locks
TCVN 4244:2005 WLL>25T 1,22WLL+20T
WLL≤25T 2WLL TCVN 4244:2005 WLL>25T 1,22WLL+20T QT 41.9
Load testing Procedure for Swivel hoist Ring/Eye bolts
4244:2005 WLL>25T 1,22WLL+20T QT 41.10 Load testing Procedure for Eye bolts/Eye Nuts
4244:2005 WLL>25T 1,22WLL+20T QT 41.11 Load testing Procedure for TurnBuckles
ASME B30.26 2WLL SWL 4SWL for single pulley SWL ≤25T 2 SWL 25T<SWL≤ 160T
0.993SWL+27T
DNV No.2.2.2
>160T 1,1SWL
ASME B30.26 WLL 2 WLL
CENTER OF INDUSTRIAL SAFETY REGISTRATION 2 LIFTING EQUIPMENTS LOAD TESTING PROCEDURE
QT41 – Version 1.2 (6/2021) Pages 2 ® Copyright of Center of Industrial Safety Registration zone 2. No Unauthorized Copying of Any Part of This Document
QT 41.13 Load testing Procedure for Personal Lifting platform/suspended Basket
ASME B30.23 R (Rate capacity)
1,5R
1,04SWL+9,6T DNV No.2.2.2
WLL≤25T 2WLL
QT 41.14 Load testing Procedure for Lifting beam/spreader bar /frames
TCVN 4244:2005 WLL>25T 1,22WLL+20T
SWL<20T 1,5SWL (static test) 1,1SWL (dynamic)
EN 13157
ASME B30.21 SWL 1,25 SWL(static test) 1,1SWL (dynamic)
QT 41.15 Load testing Procedure for Manually Operated Hoists
TCVN 4244:2005
QT 41.16 Load testing Procedure for Electrical/air powered Hoists
TCVN 4244:2005
SWL 1,25 SWL(static test) 1,1SWL (dynamic)
WLL≤25T 2WLL TCVN 4244:2005 WLL>25T 1,22WLL+20T QT 41.17
Load testing Procedure for Fibre man made slings
ASME B30.9 WLL 2WLL SWL ≤20T 1,25 SWL 20T<SWL≤ 50T
1,0SWL+5T DNV No.2.2.2
QT 41.18 Load testing Procedure for Bracket (Padeye, lifting Lug)
TCVN 4244:2005 WLL>25T 1,22WLL+20T

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