Tests and examination of Cargo Gear

Tests and examination of Cargo Gear

A record of the particulars of test and examination of lifting appliances, loose gear and heat treatment shall be entered and maintained in the Register of Machinery, Chains, etc and Wire Ropes (Form II). Certificates, in the form specified, shall be obtained from a competent person in respect of the following and attached to the Register.

1. Initial and periodical test and examination of winches, derricks and their accessory gear- Form III

2. Initial and periodical test and examination of cranes or hoists and their accessory gear - Form IV

3. Test, examination and re-examination of loose gears — Form V

4. Test and examination of wire ropes — Form VI

5. Heat treatment and examination of loose gears — Form VII

6. Annual thorough examination of loose gears — Form VIII

The register and certificates shall be kept on board the ship and produced on demand to an Inspector. They shall be retained for at least five years after’ the date of the last entry.

The register (Form II) contains the following parts

Part I — Initial and periodical load test of lifting appliances and their annual thorough examinations

Part II — Initial and periodical load test of loose gears and annual thorough examinations

Part III — Annealing of Chains, Rings, Hooks, Shackles and Swivels (other than those exempted)

No lifting appliance or loose gear, shall be used for dock work unless the entries required to be made in the register and the certificates of test and examination required to be attached are done.

Procedure for testing derricks and cranes

Before testing derricks or cranes, especially heavy lifts, the competent person must ascertain that the stability of the ship is adequate.

A derrick shall be tested with its boom at the minimum angle to the horizontal for which it is designed (generally 15°) or at such greater angle as may be agreed to. This angle shall be mentioned in the test certificate. The test load shall be applied by movable weights. During, the test the boom shall be swung, with the test load suspended as, far as practicable in both directions (P & S).

A derrick boom designed to be raised under power with the load suspended (swinging derrick) shall be raised to its maximum working angle to the horizontal with the load suspended and swung to the two outermost positions in addition to the test mentioned above.

For derricks used in the Union Purchase system, the SWL in union purchase rig must be specified by a competent person in Form III and marked on the derrick, boom. The two ginfalls must be coupled together by a suitable swivel assembly and the derricks tested at their approved working positions with a test load appropriate to the SWL in union purchase.

Cranes shall be tested similarly to swinging derricks with movable weights at maximum, minimum and intermediate radius points as well as such points in the arc of rotation as the competent person may decide. The test shall consist of hoisting, lowering, braking and swinging Through all positions and operations normally performed. All limit switches and cut-off will be tested. Additionally, the machinery shall be tested by operating it at maximum working speed with the SWL suspended.

All tests especially for new ships shall be carried out by deadweights. Spring or hydraulic balances may only be used for periodical tests, replacements or renewals. In such cases, the balance must be certified for accuracy to within 2%, by the competent authority. The test load is to be applied with the boom out as far as practicable in both directions and the pointer of the balance must remain constant at the test load for a period of at least 5 minutes.

After being tested, every lifting appliance and loose gear shall be thoroughly examined to see that no part has been damaged or permanently deformed during the test.

                                                Test Loads

Every crane /derrick and other hoisting machine with its accessory gear shall be tested with a test load which shall exceed the safe working load (SWL) as follows:
Safe Working Load..... Test Load
Upto 20 tonnes....... 25 per cent in excess of SWL
20 to 50 tonnes...... 5 tonnes in excess of SWL
Over 50 tonnes....... 10 per cent in excess of SWL
Loose gear & Wire Ropes
1. (a) Every Wire, ring, hook, chain, shackle, swivel, eye bolt, plate clampe, triangular plate or pulley block (except single sheave block) shall be subjected to a test load which shall not be less than the following:
S.W.L. (In tonnes) .............Text Load (in tonnes)
Upto 25 ............. ..................2 X Safe Working Load (SWL)
Above 25............. ................(1.22 X SWL) + 20
(b) In the case of a single sheave block, the SWL shall be the maximum load which can safely be lifted by the Block when suspended by its head fitting and the load is attached to a rope which passes around the sheave of the block and test load not less than four times the proposed safe working load shall be applied to the head of the block.
(c) In the case of a multi-sheave block, the test load shall not be less than the following:
SWL (in tonnes)............. ...Test Load in tonnes
Upto 25............. .................. 2 X SWL
Above 25 ............. ...............to 160 (0.933 X SWL) + 27
Above 160 ............. ..............1.1 X SWL
(d) In case of hand-operated pulley blocks used with pitched chains and rings, hooks, shackles or swivels permanently attached thereto, a test load not less than 50 per cent in excess of the safe working load shall be applied.
(e) In the case of a pulley block fitted with a bucket, the bucket shall be tested and the test load applied to the bucket while testing that block will be accepted as test loading of the bucket.
(f) In the case of a sling. having two legs, the safe working load shall be calculated when the angle between the legs is 90^o. In case of Multi-legged slings, the safe working load shall be calculated as per the national standards.
(g) Every lifting beam, lifting frame, container spreader, bucket, tub and other such gears shall be subject to a test load which shall not be less than that given In table below:
SWL (in tonnes)............ ............................... ....Test Load in tonnes
Upto 25 ............ ............................... ..................2 X SWL
Above 25 to 160............ ............................... ..(0.933 X SWL) + 27
Above 160 ............ ............................... ............1.1 X SWL