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Inspection of Chain Blocks and Lever Hoists

Chain blocks and lever hoists used in the offshore industry require diligent inspection and maintenance.

The offshore industry presents one of the most arduous, difficult and challenging working environments known to man. Severe weather conditions and sudden and wide variations in temperature make safety a key issue, especially where lifting gear is concerned.

All offshore equipment requires stringent examination, inspection and maintenance and chain blocks and lever hoists are no exception – the very nature of these vital pieces of equipment being that operators are relying on them to support loads or control the movement of critical appliances. Failure - leading to potential loss of life or substantial damage - is clearly not an option.

In the UK, LOLER (Lifting Operations and Lifting Equipment Regulations) now place a legislative obligation on companies owning lifting gear to ensure that all equipment is safe and suitable for its intended use and tested in accordance with rigid examination procedures. At the very least, it is recommended that operators carry out routine visual inspections before lifting equipment goes into service. It is even more crucial offshore, not least because wear and tear is accelerated at sea. Constant exposure to salt water spray quickly leads to the removal of lubricant and propagates oxidation on any affected areas as the equipment goes through a cycle of ‘wet’ and ‘dry’ operation. This is particularly true in the North Sea and Norwegian sectors.

As an absolute minimum, visual checks should be carried out each time a hand operated chain block or lever hoist is scheduled for use. Relevant and up-to-date product documentation should remain close to hand and chain blocks and lever hoists should also carry the appropriate ‘colour coding’ for the period.

Reputable suppliers recommend the following routine checks:

Hand Chain Wheel Cover:

Examine for cracks, distortion and broken parts.

Check the pitch of the hand chain within the chain wheel.

Check that the hand wheel runs freely.

Hand Chain:

Examine the hand chain for wear, nicks and corrosion.

Hand Wheel:

Check the hand wheel for wear and damage.

Brake Assembly:

Ensure the brake mechanism is operating. This may require the lifting of a light load. If the unit operates effectively with a light load, then when it is working close to its SWL it is even more likely to operate correctly.

Listen for the smooth operation of the pawls engaging in the brake disc.

The brake disc must be free of oil or grease. It may not be possible to check for this without taking the assembly apart so if there is any concern that the unit has been exposed to excesses of oil contamination it must be removed from service until it can be inspected by a qualified lifting equipment engineer.

Load Chain Dead End Pin:

Examine all anchor pins and links for distortion and wear.

Bottom Hook:

Examine the load pin for wear and tear.

Check that the hook swivels freely and there is no excessive wear on the shank.

Check the hook for stretch, distortion and wear.

In the case of multi-fall units, check the load chain sprockets for wear and ensure it rotates freely.

Check that all bearings are rotating freely and that the latch kit operates correctly.

Gear Cover:

Examine the cover for cracks, distortion and broken parts.

Load Chain:

Examine the load chain checking for bent, notched, stretched, worn or corroded links.

Internal Frame Side Plates:

Examine the body plates for alignment and ensure they are free from wear and distortion.

Check the load pin holes for signs of stretch. Where applicable, check the top hook yoke and cross bar for any distortion.

Top Hook:

Examine the load pin for distortion and wear.

Make sure the hook swivels freely and there is no excessive wear on the shank. Check the hook for stretch, distortion and wear and in the case of multi-fall units, check that the load chain sprockets rotate freely.

Check all bearings are running freely and ensure the latch kit operates correctly.

Chain Rollers, Chain Guides and Chain Stripper:

Examine the chain roller and pin, chain guide, and the chain stripper for any corrosion or damage.

Load Chain Sprocket:

Check the load chain pockets for wear ensuring that the chain sits correctly.

Bearings:

Examine all remaining bearings for free running and look for any wear and tear.

Minimising the strain

I would hazard a guess that few operators of either hand operated chain blocks or lever hoists, take the time and trouble to carry out the visual checks outlined above. As routine checks, they may seem tedious and a little over the top, but, in reality, it is a small price to pay for saving a life or preventing a disaster.

Bear in mind these visual examinations are only the first stages. Only fully qualified lifting equipment engineers should strip down items of lifting equipment, while comprehensive repair, inspection and testing requires a number of additional checks. These require specialist knowledge and should only be carried out when examiners are fully trained and the correct examination and testing equipment is available.

The Health and Safety Executive and the Lifting Equipment Engineers Association have recently established an Offshore Block Project Working Group to carry out tests to determine the impact of the sub sea operation on chain blocks and lever hoists. It is now recognised that this can be an even more aggressive operating situation, the loss of lubrication on moving components being one of many potential problems. The working group has complied a draft Code of Practice which, once finalised, is likely to be adopted across all offshore industries.

Rigging lofts

In view of the stringent health and safety requirements, many larger offshore operators are now opting to buy-in specialist testing and examination services. It gives peace of mind, and, in the long run, proves more cost effective. Certex, as an example, has introduced a Lifting Equipment Management Inspection Service (LEMIS) whereby companies are supplied with a self-contained rigging loft of loose components. The loft – often carrying up to 100 pieces of lifting tackle at any one time – arrives fully stocked and colour-coded and is routinely checked and replaced by qualified engineers every six months. The service - developed with the offshore industry in mind - allows users to re-select items as and when their lifting requirements change and predetermines running costs in advance. Reported savings of up to 15% in equipment examination and management costs make it a viable service for many users.