Sling Inspection Procedure

REV. 0

DATE 05 Mar 09

DESCRIPTION Original Issue

J

P.T . CE NT RAL JA VA PO WE R P

S UMI T O MO CO RPO RAT I O N TANJUNG JATI “B” EXPANSION C O A L - F I R E D P O WE R S T A T I O N P RO JE C T 13 SHEETS INCLUDE COVER

U N I T 3 & 4 2 x6 6 0 MW ( N E T ) MES-TSW JOINT OPERATION (MITSUI ENGINEERING & SHIPBUILDING CO., LTD.) TITLE

PM DPM

SLING INSPECTION PROCEDURE

SGM SM ORIGINATOR

I Gede Sumantra SCALE

DATE

N.A

05 Mar 09

MES JOB NO.

HB8229

MES DWG. NO.

EB-STM-SF0001

0

MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

Table of Content I.

General.....................................................................................................

2

II.

Scope........................................................................................................

2

III.

Regulation and Reference ........................................................................

2

IV.

Wire Rope Sling Requirement .................................................................

2

V.

Safe Working Load and Load Test ..........................................................

3

VI.

Sling Identification...................................................................................

4

VII.

Sling Inspection .......................................................................................

4

VIII.

Sling Storage............................................................................................

5

Attachment – Sling Inspection Sheet...................................................................

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Attachment – Table 3.21......................................................................................

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Attachment – Table 3.22......................................................................................

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Attachment – Table 3.23......................................................................................

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Attachment – Table 3.24......................................................................................

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Attachment – Table 3.26......................................................................................

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Attachment – Table 3.27......................................................................................

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MES - TSW JOINT OPERATION

I.

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

General Every slings and its accessories utilized to lift up, lift down, or to hang particular objects must be made from material with proper quality and sufficient strength to hold working load that effected by the object. Sling and its accessories must be used in proper way and to be maintained in such manner to avoid defect as twist, kink, broken wire, and any other defect. Sling and its accessories must be inspected and tested periodically to ensure them safe to be used.

II.

Scope This procedure is covering inspection for lifting slings being used in our project and is in effect to all subcontractors under MES-TSW Joint operation. This procedure is intended for wire rope sling inspection only.

III.

Regulation & Reference a. Labour and Transmigration Minister Regulation No. Per-05/MEN/1985 regarding Lifting and Transporting Equipment. b. Labour and Transmigration Minister Regulation No. Per-01/MEN/1980 regarding Safety & Health at Building Construction. c. Manual Rigging. Sri Widharto. Pradnya Paramita. Jakarta. 2003 d. Rigging and Lifting Course. PT. Industrialindo Konsultrain Service. Jakarta.

IV.

Wire Rope Sling Requirements There are six requirements to be considered prior usage of wire rope sling: 1. Wire rope must have sufficient strength to hold maximum load lifted. 2. Wire rope must be able to cope with repeated bending movement without any failure of wire caused by fatigue. 3. Wire rope must resistant to attrition / abrasion. 4. Wire rope must be able to cope with distortion and crushing. 5. Wire rope must be able to cope with rotation. 2

MES - TSW JOINT OPERATION

Project Ref Date Rev.

SLING INSPECTION PROCEDURE

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

6. Wire rope must be resistant to rust. V.

Safe Working Load & Loading Test Safe Working Load (SWL) is commonly stated by the manufacturer in the sling certificate. In case manufacturer in any reason did not able to issue sling certificate it is necessary to call for authorized third party to do loading test and issue certificate for the sling. If in case not possible to call for third party, field load test must be carried out. Some formulas to help field load test are presented below. Safety Factor In order to prevent failure of sling during operation, safety factor need to be applied. Safety factor of wire utilized for lifting material is 5 while safety factor of wire utilized for lifting personnel is 10. Maximum Save Working Load can be calculated with the formula: (Breaking Strength of Wire Rope) Maximum Safe Working Load = (Safety Factor) (Breaking Strength of Wire Rope) Maximum Safe Working Load = 5 Example: Certificate of wire rope declares Breaking Strength of Wire Rope 10 tons, the Maximum Safe Working Load will be 10/5 tons = 2 tons. Safe Working Load General formula to calculate SWL is rule of thumb. SWL = diameter of sling x diameter of sling x 8 ton Note: diameter is in inch

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MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

SWL of wire rope sling can also be calculate using Table of Safe Working Load refer to CSA G4-1967 Steel Wire Rope – General Purpose as attached. VI.

Sling Identification All sling utilized for lifting sling shall be with clear identification. Identification tag shall be posted at one end of sling with information about Sling Number, Sling Diameter, and Safe Working Load (SWL). Identification tag must be easily seen and recognized. Replace identification tag with new one if it broken.

VII.

Sling Inspection In order to ensure sling proper to use, weekly sling inspection shall be carried out by all subcontractor. Inspection to be carried out thoroughly spread all over total length of sling. Inspection of sling is carried out manually and visually. There will not be laboratory or sophisticated equipment to be used during the inspection. Check lists used during inspection are as follows but not limited to: -

Is there any twist on sling?

-

Is there any broken wire on sling?

-

Is there any kink on sling?

-

Is there any deformation on sling?

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Is there any rust on sling?

-

Is there any defect to hook?

-

Is there any defect to shackle? Result of inspection shall be noted on Weekly Inspection Report and to be

signed by safety officer. Copy of Weekly Inspection Report shall be submitted to MES-TSW Joint operation every week. Sling Inspection Form is attached. In case Weekly Inspection Report showing defect sling exceeding tolerance level, the defect sling shall not be used in operation. Wire rope sling shall not be used if there is total defect as follow: a. 12% defect of wire rope 6 x 7 from total length 50 cm 4

MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

b. 20% defect of wire rope 6 x 19 from total length 50 cm c. 25% defect of wire rope 6 x 37 from total length 50 cm d. 25% defect of wire rope 6 x 61 from total length 50 cm VIII. Sling Storage While not in use sling must be stored in roll shape and to be placed in dry clean area (indoor). In case sling must be stored outdoor means to protect sling from water, steam / vapour, impact, and in other chemical or mechanical disturbance must be provided. Keep away sling from any heat sources. Do not place sling directly on the floor to avoid sling from rusting. Periodic maintenance and inspection for sling in store must be carried out to ensure sling in safe condition.

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MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

6

MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

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MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

8

MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

9

MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

10

MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

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MES - TSW JOINT OPERATION

SLING INSPECTION PROCEDURE

Project Ref Date Rev.

: TJB Exp. Unit 3&4 : EB-STM-SF0001 : 05 March 2009 :0

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