Crane Operation & Maintenance - API Singapore 2012 Crane... · Crane Operation &...

Crane Operation & Maintenance Importance to Safety Performance

Travis Dupre Thunder Oilfield Service (Thailand) Ltd

Crane Operation & Maintenance API Specification 2C Provides standards for offshore pedestal mounted cranes. API Recommended Practice 2D Guidelines for operation, inspection and maintenance of offshore pedestal mounted cranes. Should be referenced in conjunction with Spec 2C.

How to ensure the crane is 2C

Operation & Maintenance of API Spec 2C Cranes Operation, maintenance and inspections must be performed by Qualified Personnel in accordance with API RP 2D requirements:

• Qualified Rigger • Qualified Operator • Qualified Inspector

API RP 2D Qualified Rigger:

A rigger is anyone who attaches or detaches lifting equipment to loads or lifting devices. In order to be considered a qualified rigger, the person shall have successfully completed a rigger-training program in accordance with API RP 2D.

API RP 2D Qualified Operator:

A person designated by the employer with appropriate offshore experience and training. Such experience and training must comprise of classroom-type sessions and hands-on field training on cranes specific to the type to be operated. These minimum requirements are outlined in API RP 2D.

API RP 2D Qualified Inspector:

A person designated by the employer who has appropriate experience and training, has successfully completed classroom-type training sessions on crane maintenance and hoist troubleshooting and overhaul, as well as the structural aspects of offshore cranes. These minimum training requirements are outlined in API RP 2D.

Inspection and Testing

• Inspection & Testing must meet or exceed API RP 2D recommendations

• Cranes built to API Spec 2C are to be repaired, inspected and tested following API RP 2D recommendations.

Crane Usage and Categories

Infrequent Usage - 10 hours or less per month, based on a 3 month average. Moderate Usage - more than 10 hours but for less than 50 hours per month, based on a 3 month average. Heavy Usage- cranes that are used for 50 hours or more per month.

Operator - Inspection Categories

Pre-use Inspection- prior to the first crane use of the day, each change in operator, and also as the qualified operator deems necessary during the day. Monthly Inspection- once per month, for all cranes assigned a heavy usage category.

Inspector - Inspection Categories

Pre-use Inspection & Monthly Quarterly Inspection- once every three months all cranes are assigned a moderate or heavy usage category. Annual Inspection- once every twelve months. Applies to all cranes, regardless of usage category. Initial Inspection – cranes being placed into service, being permanently relocated and temporary cranes after each rig up and relocation.

Usage/Inspection/Inspector Matrix Usage Category

Infrequent Moderate Heavy

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QI or QO QI or QO QI or QO

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Qualified Inspector or

Qualified Operator

Qualified Inspector Only

No Inspection Required

Inspection & Load Test Records

• A log of pre-use inspections should be maintained.

• Initial, monthly, quarterly and annual inspection reports, as well as records of repairs and modifications carried out on cranes in accordance with this Recommended Practice should be kept readily available for a period of 4 years at an appropriate location.

Inspection Topics to Remember

• If a crane is operated more than 50 hours in one month period, it immediately falls in to the heavy use category.

• A quarterly inspection should be performed in the event a crane's duty cycle increases from infrequent usage to a higher usage category.

• An annual inspection should not exceed twelve months from the last inspection.

• Should the owner choose not to track usage the crane will automatically default to heavy use category.

Repairs and Replacements If unsafe conditions are identified during the inspection, the crane shall be taken out of service or its operation restricted to eliminate the unsafe condition. All major replacement parts should equal or exceed the OEM’s recommendations.

Welding Repairs No welding repairs shall be made to critical components, such as booms and swing circle assemblies without specific repair procedures and recommendations from the OEM, or other qualified source (such as an API licensed 2C crane manufacturer, authorized surveyor, or an engineer experienced in the design of the crane, as determined by the owner).

Critical Components A critical component is any component of the crane assembly whose failure would result in an uncontrolled descent of the load or uncontrolled rotation of the upper-structure. These components are required to have stringent design, material, traceability and inspection requirements.

Preventive Maintenance

A preventive maintenance program should be established by the owner. The referenced inspections criteria of 2D should NOT be considered a Preventative Maintenance program, however it is possible to integrate the programs.

Record Retention The manufacturer shall maintain all inspection and testing records for 20 years. These records shall be employed in a quality audit program of assessing malfunctions and failures for the purpose of correcting or eliminating design, manufacturing or inspection functions which may have contributed to the malfunction or failure.

Without Spec 2C & RP 2D =

Bathtub Curve

API Spec 2C & RP 2D = Reliability

Importance to Safety Performance

Consequently, understanding how the documents relate to one another directly impacts safety performance in concerns to offshore pedestal mounted crane operations and maintenance.

Thank you!