SOP Overhead Crane-Rev.1

STANDARD OPERATING PROCEDURE SOP Number
Page 1 of 5
OVERHEAD CRANE INSPECTION SOP-005/BKI/CIT/10
Rev. Number Issued Effective
Chevron Kalimantan Operation 01 June 15, 2011 June 17, 2011
OVERHEAD CRANE INSPECTION
Facility/Section:
Area/Dept.:
Rev. Rev. Date Description Prepared by Reviewed by Approved by

Number BKI Team CICo. CICo.
New Issue
June 15, Whole
01 ___________ ___________________
2011 Document
Partial
Operational
Page 1 of 5
Excellence
Management
Chevron
System
Kalimantan
Operation
1 STANDARD AND SPECIFICATION
- IBU Lifting and rigging standard

- ANSI B30.2 Overhead and Gantry cranes
- ANSI B30.11 Monorail system and Under hung cranes
- ANSI B30.16 Overhead Hoist
- ANSI B30.17 Single Girder Top Running cranes
- Other code and Standard
2 GENERAL DESCRIPTION
This procedure covers the requirements for annual inspection of overhead crane and to give
direction of inspector to carried out the inspection
3 SCOPE OF INSPECTION
1. Document Review
2. Visual and Dimension Check
3. Function test
4. NDT (Non Destructive Test)
4 HES NOTICE
Some possibility of personal injury may occur before and during activities. The inspector has injury
possibilities to i.e. finger pinch, back injury and falling down.
5 PROCEDURAL STEPS
Action Remark
Action
Number (who & when)
I. Preparation
1 Prepared Work Permit and inquiry for approval BKI
2 Conduct safety talk, and determine specific job BKI
3 Prepared tools, NDT equipment, and PPE BKI
II. Execution
Evaluate working area to ensure that its area is safe during
1 BKI
perform the job
INSPECTION ;
2.1. Structure
- Girder, check the condition of boom for sign of crack,
bend and corroded members
2.2. Gantry, Runway and rail

- Check the condition of gantry, runway and rail for sign
of crack, bend and corroded member
- Condition of rail shall be clean and free from paint, oil
and grease, because it will cause slip or wheel sliding
2.3. Drum.
- All drum shall be provide a first layer rope pitch
2 diameter of not less than 18 times the nominal rope BKI
diameter used.
- The flange shall extend a minimum of 2½” over the
top layer of rope at all times
- Rope drum (electric or air power hoist) shall be
grooved except when the hoist is provided by the
manufacturer for a special application, the grooves
shall be free from surface defects that could cause
damage
- No less than two (2) full wraps of rope shall be remain
on the drum in any operating condition
- Check for cracked or worn
- The drum end of the rope shall be anchored to the
drum by arrangement specified by the crane or rope
manufacture
2.4. Brake and Clutch
- Check the control mechanism of brakes and clutches
for proper operations
- Check for leakage and damage in air and hydraulic
system
- Verify condition of all braking system
2.5. Wire Rope
- Visually all wire rope for deterioration and damage

such as kinking, bird caging, crushing, corroded or
broken at the end connections
- Check that it correct size and rope is properly fitted
- Wire rope tester (electromagnetic inspection) shall
carried out over the length of the wire rope
- Replacement of wire rope
 Running ropes ; twelve (12) randomly
distributed broken wires in one (1) lay or four
broken wires in one (1) stand in one(1) lay
 Wear of one-third the original diameter of
outside individual wires
 Kinking, crushing ,bird caging, or any other
damage resulting in distortion of rope
structure
 Evidence of heat damage from any cause
 Reductions from nominal diameter greater
than those listed below
Maximum Allowable Reduction From
Rope Diameter Nominal Diameter

Up to 5⁄16 in. (8 mm) 1⁄64
in. (0.4 mm)
Over 5⁄16 in. to 1⁄2 in. (13 mm) 1⁄32
in. (0.8 mm)
Over 1⁄2 in. to 3⁄4 in. (19 mm) 3⁄64
in. (1.2 mm)
Over 3⁄4 in. to 11⁄8 in. (29 mm) 1⁄16
in. (1.6 mm)
2.6. Wedge Socket

- Verify that the socket and wedge are correct size for
the rope in use
- Check the socket eye and pin for roundness and wear
A pin Keeper should always use with the pin
- Check socket and wedge for rough edges or burn
- Wire rope clips used in conjunction with wedge
sockets shall be attached only to the unloaded (dead
end) of the rope
- Ensure that the live end of the rope is on the straight
side of the socket and dead end on the tapered side
of the socket
2.7. Hook
- Hook shall be discarded where throat opening is 15

% more than original throat opening and also bending
or twisted more than 10 deg from plane of the unbent
hook
- Any wear exceeding 10% of the original section
dimension of the hook or its load pin
- Repair by welding or reshaping are not recommended
2.8. Sheaves
- Check sheaves for Wear and corrugation , broken or

chipped flange, crack in the hub, freely rotating
without drag
- Check of dimension sheaves groove with sheaves
gauge
- Make sure the sheaves shall comply with diameter
wire rope to be used
- All Sheaves including running block should be
provided with guards or suitable devices to prevent
the rope from coming out of the sheaves groove
2.9. Controls and Miscellaneous
- Check the control operations shall be clearly marked

and easy visible
- Function test of overload protective device (if any),
limit switch, anti two block system
- Function test of ESD ( emergency shut down )
Non Destructive Test(NDT)
3 - Perform NDT of Hook and wedge socket and other BKI

suspected area such as welding connection at girder etc.
- Perform wire rope test
Testing
Operating and function test shall include the following:

- Load hoisting and lowering mechanism
4 - Traversing of trolley BKI
- Traveling of gantry and or girder
- Safety devices such as power driven start stop, load hoist
limit, limit devices, anti two block, ESD, Alarm or horn
- Perform all braking system
Load Test (if required)

5 BKI
5.1. Dynamic test
Each crane should be given a dynamic test to ensure
crane capacity, dynamic testing should include the
following crane capacity :
- Hoisting and lowering load with 25%,50% and
100% of Safe Working Load (SWL)
- Traveling and traversing load with 25%,50% and
100% of Safe Working Load (SWL)
5.2. Static load test
The purpose of the static load test to verify that the

structure and other components are still good condition,
the static load shall not exceed 125% of the rated
capacity, load shall be placed in the middle of girder
and maximum deflection shall be not greater than 1/
700 x span length.
Inspection after Testing
Purpose of inspection is to verify and ensure the condition of

6 the crane after load test BKI
- Visual inspection such as structure, wire rope, bolted and
welding connection, etc
- NDT for critical area, Hook and Wedge socket
Reporting
Any defects or deficiencies of the crane found either during

inspection or after completed, should be discussed with the
owner/user, and if necessary recommend corrective action.
Report consist of :
7 BKI
1. Certificate of inspection
2. Check list
3. Finding inspection
4. NDT report and dimensional check report
5. Wire rope test record
6. Load test report
III Completion
1 House Keeping BKI
2 Close out Work Permit BKI

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STANDARD OPERATING PROCEDURE SOP Number

OVERHEAD CRANE INSPECTION

Rev. Rev. Date Description Prepared by Reviewed by Approved by

1 STANDARD AND SPECIFICATION

- IBU Lifting and rigging standard

2.2. Gantry, Runway and rail

2.5. Wire Rope

- Visually all wire rope for deterioration and damage

Rope Diameter Nominal Diameter

2.6. Wedge Socket

- Hook shall be discarded where throat opening is 15

- Check sheaves for Wear and corrugation , broken or

2.9. Controls and Miscellaneous

- Check the control operations shall be clearly marked

Non Destructive Test(NDT)

3 - Perform NDT of Hook and wedge socket and other BKI

Operating and function test shall include the following:

Load Test (if required)

5.2. Static load test

The purpose of the static load test to verify that the

Inspection after Testing

Purpose of inspection is to verify and ensure the condition of

Any defects or deficiencies of the crane found either during

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