Crane thorough inspection report

Dated: 30th June 2013 Time: 1030 H Location: Turk Facility Crane type: Telescopic boom hydraulic crane Crane Plate no: JS-0218 Lifting activity: Offloading of (02) 20 ft containers and water holding tank at Turk Facility Category of lift: simple

The details of minor defects and recommendations/actions for crane are as follows. 1. Thorough examination certificates/NDT reports were not available for secondary equipment such as: - Main hook block, open wedge socket, open wedge socket anchor point (pad eye), main hoist wire rope manufacturer certificates, main hook block and any other lifting accessories located on the mobile crane 2. Outrigger lock pins were not installed. 3. Hydraulic fluid tank was dented; however there was no evident sign of leakage. 4. Boom tip sheaves flanges were worn/bent and should be replaced immediately (see fig A). This is caused to side loading the boom while lifting the load. The diameter of wire rope was 18 mm and the sheaves valley and grooved winch drum were also designed for 18 mm wire rope .The flanges of sheave arent load bearing but usually the crack propagates from the flanges. No cracks were observed, however the localized wear will result in crack which can propagate to the sheave valley and consequently result in load failure. There was no wear observed in the valley of the sheave groove. 5. Main hoist wire rope was incorrectly terminated into the open wedge socket. Bulldog grips were incorrectly installed onto the open wedge socket. There was also a sizeable play in the wedge socket (see fig B), the rigger was told to put flat washers to reduce this play. Wedge socket pin was worn but within allowable 10 % wear limit. 6. Main hoist wire rope was completely inspected. Broken wire ropes were observed at places (maximum 2 wires broken in one lay length, 6 X 36, IWRC, 18 mm wire rope) but were within allowable limit. Diameter reduction was observed at places but was within allowable limit (10 % reduction). Protruding broken wire ropes damage the sheaves so any such wire ropes were cut during inspection. It is recommended to periodically monitor the deterioration and replace the wire rope within 6 months time. 7. The roller guides on boom were stuck (see fig C). This results in mechanical wear of wire rope on contact. The crane operator was informed to periodically lubricate the rollers.

8. Electrical wire connections (see fig D) were improper for working inside hydrocarbon facility (hazardous area). These can act as ignition source in a hydrocarbon rich area. Provide proper electrical contacts (male /female thimbles) with proper hydrocarbon zone rating/area classification. 9. Crane Tires were worn and damaged. Some need to be replaced right away and some can last up to 3 months maximum (see fig E). 10. Drive rod end bearing rubber packing was damaged. Replacement required (see fig F) 11. Front wheel shock absorbers rubber packing was damaged. Replacement required (see fig G) 12. Hydraulic pipes on outriggers were damaged. Replace immediately (see fig H)

Fig A: Boom tip groove sheave bent. To be replaced immediately.

Fig B: Sizeable play. Provide washers to reduce it.

Fig C: Roller guides stuck

Fig D: Electrical wires connections

Fig E: Crane tyres worn and cracked. The ones encircled in yellow can rupture under increased pressure. Immediate replacement required.

Fig F: Rubber packing damaged.

Fig G: Rubber packing damaged- Front tyres shocks absorbers.

Fig H: Hydraulic pipe damaged. Replace immediately.