Accreditation Requorements of Inspection Bodies for Lifting Equipment

DUBAI ACCREDITATION DEPARTMENT – DUBAI MUNICIPALITY

This is an official document of DAC; The Printed co py of this document shall be treated as ‘Uncontroll ed’. Always refer to the controlled version Online.

ACCREDITATION REQUIREMENTS OF INSPECTION BODIES FOR LIFTING

EQUIPMENT

(ALL TYPES OF CRANES, HOISTS, SUSPENDED EQUIPMENT, ESCALATORS, ELEVATORS AND OTHER LIFTING EQUIPMENT U SED

IN CONSTRUCTION SITES AND INDUSTRY)

DAC-REQ-06 January 2009

DUBAI ACCREDITATION DEPA RTMENT – DUBAI MUNICIPALITY


2 of 25 DAC-Req-06 Issue. 2, Rev. 2 January 2009

CONTENTS

Foreword……………………………………………………………………………… 3 1 Definitions……………………………………………………………… 4 2 Scope…………………………………………………………………… 9 3 General Requirements………………………..……………………… 11 4 Specific Criteria of Competence………………….………….……… 12 4.1 Requirements for Technical Competence of Staff………………… 12 4.2 Requirements for Site work. ………………………………………… 15 4.3 Inspection Methods and Procedures……………………..……….… 16 4.4 Internal Quality Audits………………………………………………… 17 4.5 Equipment Used for Inspection …………………………………… 18 4.6 Inspection Certificate/Report ………………………………………... 18 5 Accreditation Certificate……………………………………………… 21 6 Surveillance……………………………………………………………. 21 7 Accreditation Fees……………………………………………………. 22 8 Accreditation Requirements…………………………………………. 22 9 References…………………………………………………………….. 22 Annex 1 List of Standards.……………………………………………………... 23 Annex 2 Onshore “Lifting Equipment” Frequencies for Testing/Inspection.. 25




FOREWORD Dubai is a rapidly expanding Emirate, and the Government places great emphasis on providing quality services. The main role of DM is to formulate the Emirate’s urban strategic plans as well as the provision of essential infrastructure, environmental and health services for the continued development of Dubai as a modern, safe and dynamic Emirate. The DM, through its Dubai Accreditation Department (DAC) undertakes assessment and accreditation of various Conformity Assessment Bodies (CABs) according to International Standards, guidelines and world best practices. The requirements for accreditation of Inspection Bodies are basically the ISO/ IEC 17020 as well as the criteria for performing testing and inspection according to the technical standards defined in the scope of accreditation by each CAB. This document DAC-Req-06 describes the requirements for accreditation of inspection bodies working in the field of lifting equipments inspections for all types of cranes, suspended equipment, construction hoists, elevators, escalators and other man-lifting equipments under the accreditation program operated by the Dubai Accreditation Department (DAC) of Dubai Municipality. This accreditation program is being implemented in order to provide a means of assessing and accrediting the competence of the inspection bodies to carry out inspections and related activities for the requirements of Dubai Municipality pursuant to the local order 61/1991.

This document should be read in conjunction with the International Standard ISO/ IEC

17020:1998, General criteria for the operation of various types of inspection bodies, ILAC (International Laboratory Accreditation Cooperation) /IAF (International Accreditation Forum) joint publication IAF/ILAC A4:2004 Guidance on the Application of ISO/IEC 17020 and DAC document DAC-Reg-01, Accreditation Requirements.

DAC-Req-06 has been produced by DAC in cooperation with the Technical Committee for Accreditation of Inspection Bodies. DAC-Req-06 shall be used for accreditation of Inspection Bodies performing inspection of lifting equipment. It is also intended to assist employers to select 'competent persons' for the purposes of The Lifting Operations and Lifting Equipment Regulations 1998 (LOLER). While accreditation will normally be an indication of the quality of services offered by the inspection bodies, it should not be regarded as a guarantee that the inspection body will always maintain a particular level of performance. It shall not, in any way, diminish the contractual obligation between the inspection body (IB) and its clients. It is subject to revision periodically when deemed necessary. It is the responsibility of the IB to ensure that the latest version of this document is available for reference and implementation.




1 DEFINITIONS

The purpose of this section is to define the general and technical terminology that is used throughout this document.

1.1 Lifting Equipment Any lifting machine, driven by manual or mechanical power that is able to

raise, lower or suspend loads, and includes the supporting structure and all plant, equipment and gear used in connection with such a machine, but excludes continuous mechanical handling devices (i.e. conveyors) such as but not limited to: -

i. Cranes (tower, mobile etc), ii. Wall / Pillar Cranes, Derricks, Swing Jibs and Davits, iii. Runway Beams, Monorails, All Pad Eyes, Gin Poles and Gin Wheels, iv. Winches, Hoists (air and electric), Crabs, Telfer Hoists, v. Chain Blocks, Wire Rope Pulling Machines, Pull Lifts, Trolleys, vi. Powered working Platforms, vii. Elevators and Lifts, viii. Forklifts, Self Loader and Side Booms, ix. Lifting Jacks (pneumatic or hydraulic).

1.2 Lifting Accessories or Loose Gear (also known a s Lifting Jackets)

Any item used to connect a load to the lifting equipment but which is not in itself a part of the load or the equipment, such as:

i. Chains and Wire Ropes, ii. Chain, Wire Rope and Webbing Slings, iii. Rings, Links, Hooks, Shackles, Eye Bolts, Swivels, Blocks, Snatch Blocks, iv. Beam Clamps and Plate Clamps, v. Lifting Beams / Spreader Beams.

1.3 Substantial / Major Alteration

A measure whereby the equipment undergoes a change to either the quantum of its load lifting capacity, or changes to its function or methods of controlling those functions.

The following shall be considered “Substantial / Major alterations” or any other measure not specifically detailed that affects the safe use of the equipment:

i. Increase of the safe working load or an increase in performance, ii. Increase of the rated speeds, iii. Increase of the reach (outreach, lifting height, etc), iv. Alteration to safety devices, v. Alteration to load carrying parts (e.g. anchorages, spelter sockets, primary




structures etc), vi. Alteration to driving mechanisms and controls, vii. Repair or alteration that affects strength and / or stability, viii. Alteration of kind of current or voltage, ix. Alteration of kind of guiding rails, x. Alteration of kind of number of landing doors.

1.4 Repair

A measure whereby the original state of equipment will be restored by rebuilding or exchanging parts or units. If essential parts with safety functions are to be rebuilt or exchanged, this is considered to be a “Major Repair”. This is the case particularly in respect of the exchange of the following:

i. Brakes, ii. Safety Gear or catching devices, iii. Over-Speed Governors, iv. Load carrying parts (e.g. anchorages, open or closed spelters sockets,

primary structures etc), v. Driving mechanisms and controls.

Repair also includes the replacement of a part or a complete assembly if the part or the complete assembly is covered by a certificate for its capacity or performance by the manufacturer of either the part/assembly or of the original equipment.

1.5 Inspection

Any physical activity, related to ensuring that an item of “Lifting Equipment”, in its entirety and at a given location or environment, meets the specified design and operating Standards and is safe to operate or utilize for a specified period. This includes, but is not limited to, activities such as measuring, testing, recording, checking, analyzing, loading and charting one or more characteristics of the equipment.

1.6 Periodic Inspection

The minimum, specified period, denoted in days, weeks, months or years, between one “Inspection” and a repeat or next “Inspection” as per Annex 2.

1.7 Load

Means any material, persons, or any combination of these that are lifted, lowered or suspended by the Lifting Equipment. The weight of the lifting accessories including the hook block may be considered as part of the load being lifted, as applicable by the relevant Standard.




1.8 Working Load Limit (WLL) Means the maximum load (mass), which any piece of lifting equipment may lift safely in the most efficient configuration. For wire rope, chain and fiber rope slings this is in direct lift i.e. eye to eye in a straight vertical line.

1.9 Safe Working Limit (SWL) Means the maximum load (mass), which any piece of lifting equipment may lift safely in a particular configuration, other than its most efficient configuration. e.g. for a wire rope sling choked on a square load without any corner protection its safe working load is approximately 50% of its WLL.

1.10 Proof Load Test The application of a predetermined load excess of SWL to assess the ability

of the equipment to withstand operation requirements. This applied proof load shall never exceed the elastic limit of the item being tested.

The amount of Proof Load to be applied will vary depending upon the type of equipment, its SWL, and the applicable Standard (refer to Annex 1).

On completion of any proof load test, the “Lifting Equipment” is to be fully inspected to ensure that the structural integrity of the equipment has not been impaired.

1.11 The Minimum Breaking (or Failure) Load (MBL )

It is the theoretical load below which a sample of the item will not break or fail, when new.

1.12 Factor of Safety (FOS) or Coefficient of Uti lization or Working Coefficient

It is a factor that is applied to the MBL to determine the WLL (working load limit). It varies with the product to take account of the susceptibility to damage and considers the type of stresses the item will withstand in normal use. Where the conditions of use are more severe than those considered by the product standard, the user would apply an increased FOS, so reducing the value of the SWL from that of the WLL.

1.13 Inspection Certificates (of Lifting Equipment)

All original Inspection Certificates issued by a DAC accredited IB, to indicate compliance of lifting equipment with safety requirements and its fitness for use, shall be a Certificate both in name, detail and format. Each certificate shall contain the minimum details as specified under section 4.6.2.

A Certificate shall not be issued where the lifting equipment does not comply fully with the requirements of the relevant Standards and the requirements of this document.

The certificate shall be signed by the authorized Inspector who has performed the inspection, or by any other appropriate authority assigned by the IB.




Computer-generated or rubber stamped signatures are not allowed on the certificates. Certificates not conforming to the above requirements shall be rejected.

1.14 Inspection Report (of Lifting Equipment)

When the lifting equipment does not comply with the requirements of the relevant standards, an Inspection Certificate cannot be issued. Instead an Inspection Report shall be issued which shall contain the applicable information referred to in clause 4.6.2 of this document; in addition to the full description as to why the lifting equipment failed the inspection.

1.15 Non-destructive testing NDT

Testing carried out on the structure of the lifting equipment to establish the presence, location and extent of any defects that can affect the integrity of that structure. NOTE: The techniques employed for non-destructive testing are such that they do not damage or alter the material under test. NDT is also known as non-destructive examination (NDE).

1.16 Critical Components and Areas

It means those components and areas that if failure occurs the lifting equipment may become unstable and/or cause the load to fall.

1.17 Thorough Inspection It means the following items shall be checked for compliance with manufacturers’ specifications and safe operation, as a minimum: • Oil levels, fuel level and lubrication. • Ropes, rope terminal fittings and anchorages, rope drums and sheaves for

any damage and wear. • All water is drained from air reservoirs. • Crane for any loose or damaged structural component including supports

and outriggers where fitted. Loose joints may be readily noticed by flaking or marking on the paint surface or by rust marks. Similarly, cracks may often be detected by rust runs.

• Security of the counterweight. Where this is in the form of removable weights, checking that the weights correspond to those shown on the counterweight chart for the operating condition in use.

• Load moment system where fitted is correctly set or fitted (or both) with the program appropriate to the boom or jib length, and fly-jib lengths and falls or parts of rope.

• Indicator appropriate to the boom, jib or fly-jib length is fitted.




• Crane cabin is in a tidy condition and free from grease and oil, rags, tools and materials other than those for which storage provision is made.

• Pneumatic systems and hydraulic systems including their safety devices. • Operation of the crane through all motions with particular attention to

brakes. • Operation of all limit switches or cut-outs and safety devices. Caution

to be exercised in making the checks in the event of non-operation. • Where telephone or radio communications are being used, the calling

signal is functioning and any messages may be clearly heard. • fire extinguishers are in place and satisfactory for use. It is normally not necessary, unless there is some noise or other indication, to remove covers or open gearboxes while undertaking a ‘Thorough Inspection’

1.18 Periodic inspections This means an inspection based on the working environment, the frequency and severity of use of the lifting equipment and in no circumstances shall the inspection interval exceed 12 months. The inspections shall include all items specified by the manufacturer for annual inspection together with all routine inspection items. If the manufacturer’s recommendations are not available a competent person must specify, in writing, all the items/components to be inspected together with the acceptance/rejection criteria, which must be applied by the Inspector.

NOTE 1: The 12 month inspection period is based on a normal working day of up to 8 hrs and a 5/6-day working week (2400 hours). When usage of the lifting equipment exceeds these figures a competent person must specify exactly, in writing, what the period of these inspections is. NOTE 2: As the result of a periodic inspection, a competent person may recommend a major inspection.

1.19 Major inspection

The following cranes shall be subjected to a major inspection to assess their suitability for continued safe operation: (a) Cranes that have reached the end of their design life or, where this is

unknown, after 25 years for the structure and 10 years for the mechanical components.

NOTES: 1. A crane’s design life may not be the same as its actual life and depends

on such factors as its classification, usage and its operating environment.




2. Devices are available to record the actual usage of a crane to enable assessment of its remaining design life. Guidance on condition monitoring is given in ISO 12482-1.

(b) Old cranes that are to be re-commissioned and that do not have previous

operating records or that were designed and built to unknown Standards. (c) Cranes that are to be upgraded or modified. In carrying out a major inspection, attention shall be given to the following: (i) Structural, mechanical, electrical, instrumentation, control and operational anomalies. (ii) Non-destructive examination to an appropriate Standard. (iii) Controls and emergency stop. (iv) Braking systems. (v) Manufacturer’s safety upgrades. (vi) Adequacy of safety instructions and manuals. (vii)The capacity and viability of upgrading the crane to the requirements of

the latest Standard.

The crane shall undergo further major inspections when deemed necessary by a competent person.

1.20 Related Authority Dubai Municipality (DM) - Environment Protection and Safety Section in the Environment Department (EPSS) and Engineering Supervision Section in the Building Department (BD), Department of Civil Aviation, Dubai Ports Authority-Ports Customs & Free zone Corporation, Jebel Ali Free Zone Authority (JAFZA), Dubai Civil Defense.

1.21 Shall

The word Shall is used when stating a mandatory requirement.

1.22 Should The word Should is used when the statement is advisory.

2 SCOPE 2.1 DAC-Req-06 covers the in-service inspection of lifting equipment, which

includes inspection that is undertaken after installation and prior to being put into service. Inspection bodies accredited under this accreditation program provide one or more of the following services:

(a) Development of schemes of in-service inspection;




(b) In-service inspection of equipment to detect actual and incipient defects and judgments on the significance of such defects for continued safe use. If a defect is identified by an IB, its significance shall be made clearly known to the person responsible for the operation of the equipment.

E.g. if a component is cracked and it shall not continue in use until appropriately repaired or replaced, the IB must advise (in writing) the owner or his representative of this fact before leaving the site;

(c) Reporting the result of the in-service inspection, specifying any repair service or replacement action and/or recommendations necessary to return the lifting equipment to a state of compliance with the appropriate standards referred to in the Annex 1;

(d) Inspection during or following repair service or replacement action; (e) Commenting to DAC on the suitability of, and any changes necessary to, Inspection methods/ schemes of in-service inspection.

2.2 In-service inspection of lifting equipment performed onshore only may be

accredited using this document, for offshore this will be handled in the future. 2.3 The scope of activity of in service inspection for which accreditation is granted

may be described in the accreditation scope for each IB as Powered Lifting Equipments, Manual Lifting Equipments or Lifting Accessories as defined in section 2.4 and 4.3 or by reference to the specific type of lifting equipment (e.g. window cradles or tower cranes).

2.4 The accreditation program shall cover the inspections of the following classes

of lifting equipments: 2.4.1 Class 1: Powered Lifting Equipment

Powered lifting Equipment cover a wide range of Equipment used for lifting load either vertically or horizontally or both and mean any stationary or mobile Equipment including attachments for anchoring, fixing or supporting that Equipment, which is operated by means of motive power e.g. electric, hydraulic or pneumatic or other powered means. Examples are like: Mobile Cranes, Overhead Cranes, Tower Cranes, Crawler Cranes, Gantry Cranes, Jib Cranes, Slewing Jib Cranes, Derrick Cranes, Construction Hoists, Cradles, Elevators, Escalators, etc.

2.4.2 Class 2: Manual Lifting Equipment

Manual lifting appliances cover a wide range of Equipment used for lifting and mean any stationary or mobile Equipment including attachments for anchoring, fixing or supporting that Equipment which is operated solely by means of the operator without any powered assistance.




2.4.3 Class 3: Lifting Accessories or Loose Gear (Attachments or Lifting Gear, also known as Lifting Jackets) Lifting Accessory covers the whole range of equipment used for attaching loads to Lifting Appliances. Examples are like Runway Shackles, Slings, Rings, etc.

2.5 Subcontracting: 2.5.1 Where the inspection body subcontracts certain specialized activities

temporarily for part or all of its inspection activities for unforeseen extra work load or any other reasons there must be identifiable member(s) of the management personnel sufficiently knowledgeable in those technical activities being subcontracted, to be able to: (a) Define the problem adequately to enable the subcontractor to offer

appropriate services, personnel and equipment; (b) Choose an appropriate subcontractor and to assess its technical

competence (e.g. methods, personnel and facilities); (c) Interpret the results supplied by the subcontractor and relate those

results properly to the service originally requested or problem originally defined..

2.5.2 If the inspection body subcontracts any part of its DAC accredited activities

covered in the scope of this document, the subcontractor must be accredited by DAC.

2.5.3 As for NDT activities; when the inspection body subcontracts any of such

activities related to lifting equipment inspection, the inspection body must use a competent subcontractor, which is complying with the criteria stipulated in the relevant standard of ISO/IEC 17000 series; i.e. clause 14.4 of ISO/IEC 17020 or clause 4.5 of ISO/IEC 17025

3 GENERAL REQUIREMENTS 3.1 The Inspection Body applying for accreditation as per this program must have

a management system, which includes the following as minimum: 3.1.1. Proper Documentation of its policies, procedures and operations starting from

receiving the request for an inspection, carrying out contract review, preparing for inspection, performing inspections, recording results and up to the issuance of the final report/ certificate in accordance with the documentation requirements of ISO/ IEC 17020:1998 “General criteria for the operation of various types of bodies performing inspections” and any additional




requirements set by DAC here within this document and other related documents.

3.1.2. Facilities properly equipped with the equipment and instruments appropriate for the type and range of inspections under accreditation as minimum.

3.1.3. Employ the suitable and qualified technical and administrative staff in the inspection body (see 4.1 also).

3.2 For commercial private inspection bodies, the IB must posses a professional

license from the Department of Economic Development and registered to operate in Dubai under Local Order 52/1990 and must have passed the adequacy and compliance audits as per the requirements of the local order. Inspection Body shall obtain Environmental clearance (No Objection Certificate) from the Environment Protection and Safety Section in the Environment Department before starting their initial operation.

3.3 The Inspection Methods to be accredited must be included in the official list of

tests submitted by the inspection body (Local Order 52/1990 DM Form 4). 3.4 The Inspection body shall operate in accordance with the requirements of

ISO/ IEC 17020:1998 and the relevant standard of inspection and test methods according to which it would be accredited as well as the Technical Guidelines 41 issued pursuant to the Local Order 61: 1991.

3.5 The Inspection Body shall prepare work program for its activities with a

frequency suitable to its nature of work. 3.6 The Inspection Body shall have clear rules for the fees charged for the

Inspection Services and for the issuance of the Certificate; and the terms of payments for each. Fees charged by Inspection Body shall be for the Inspection Services and not for the sake of issuing a Certificate; the fee shall be chargeable even if a certificate is withheld.

4 SPECIFIC CRITERIA OF COMPETENCE 4.1 Requirements for Technical Competence of Staff 4.1.1 The inspection body shall use personnel to carry out inspections of lifting

equipment who have the qualifications, training, experience and knowledge of the requirements of the inspections to be carried out. The inspection body shall maintain records of such qualifications, training and experience, and records to show how and when, each personnel was authorized to perform specific in-service inspection activities, the scope for which he is authorized and the sample of his signature. These records shall, as a minimum, indicate




the class of lifting equipment as defined in clause 2.4 above, considered to be within the competence of that personnel.

4.1.2 The inspection body shall only authorize personnel to carry out in-service

inspections of lifting equipment if the inspections are within the designated competence of that personnel and if that personnel holds the Category of qualification necessary to inspect the types of the equipments as shown in clause 2.4 and defined in section 4.1.4.

4.1.3 Where the personnel of the Inspection Body carry out in-house calibrations of

inspection, measuring and test equipment, the records of their training, qualifications and experience shall be maintained together with details of who is authorized to perform specific calibrations.

4.1.4 Educational Background and Qualifications:

Inspection Body shall ensure that the competent personnel carrying out a thorough examination has such appropriate practical and theoretical knowledge and experience of the lifting equipment to be thoroughly examined as will enable them to detect defects or weaknesses and to assess their importance in relation to the safety and continued use of the lifting equipment. The inspection body shall have at least one or two senior permanent staff as follows:

• Chief/ Senior Inspector (or however named): at least 15 years of hands-on

experience within a relevant engineering discipline of which at least 10 years shall have been spent working within an engineering discipline related to lifting equipment, or, if he holds B.Sc. Engineering Degree, shall have at least 8 years experience with minimum 4 years working within an engineering discipline related to lifting equipment.

• Inspectors: at least 3 years hands-on experience spent working within an

engineering discipline related to lifting equipment, or if he holds B.Sc. Engineering Degree, shall have at least 1 years experience working within an engineering discipline related to lifting equipment.

No inspector is allowed to perform inspection independently without having appropriate qualification and training. The inspection body shall assess the competence of all categories of persons mentioned above and this assessment shall cover relevant knowledge of the relevant laws, local & admin orders, codes of practice and inspection techniques. DAC shall be given the opportunity to review the means of such an assessment.

4.1.5 Levels of Supervision and Requirements for Technical Support:




The extent and frequency of supervision and technical support exerted by the inspection body management over its staff must be proportional to the volume of work taken by the inspection body, the level of experience and training of the technical staff, the criticality of equipment under inspection and existence of regulatory requirements for the concerned field of inspection. No under-training-inspector shall be allowed to perform inspection activities independently under any circumstances. Following are the classified levels of supervision that must be exerted by the inspection bodies and circumstances under which they shall be exerted:

• Occasional (on Senior Inspectors)

Formal, direct contact to review work with Supervisor at least annually. If the senior inspector is the highest level of competence in the IB then he is responsible for holding sufficient records that review of his work has been done as per this requirement either by him or by any of his peers. More frequent direct contact with Supervisor may be necessary. Technical support from persons qualified to peer senior inspector to be readily available.

• Frequent (on inspectors) Direct contact with Supervisor at least weekly. Technical support from persons qualified to senior inspector.

• Constant (on inspectors under-training) Direct daily contact with Supervisor. Technical support from persons qualified to Senior inspector or inspector to be readily available.

4.1.6 Training and further development:

4.1.6.1 The training provided by the Inspection Body to its staff shall provide a working knowledge of the plants or construction sites or other locations (where equipment are used), equipment and systems including design construction, operation, maintenance, significance of defects, typical problem areas and associated method of rectification. DAC recognizes training provided by world reputable training organizations like (but not limited to) Lifting Equipment Engineers Association (LEEA).

4.1.6.2 The training shall include the safe conduct of the inspectors’ duties, in particular safe practices applicable to lifting equipment, risk assessment, knowledge of applicable statutory requirements, codes of practice and standards.

4.1.7 Assessment of inspectors for the purpose of accreditation: Inspectors will be assessed by witnessing their performance in the field. Not all inspectors may be assessed during the first visit but all inspectors will be assessed within the 3-year validity period of the accreditation.




4.2 Requirements for Site 1 Work

4.2.1 Preparation for Site work:

(a) Prior to going to site, the Inspection Body must ensure the following: • All needed Personnel Protective Equipment that ensure safety of

personnel on site are taken to site; • Critical test equipment must be checked prior to leaving secure storage

before inspection; (b)The Inspection Body shall allocate inspection activities based from the

work program for each inspector in the form of Work Orders. Work Orders to be used by inspectors on site shall contain the following information as minimum:

• Identifiable number traceable to the client request/ contract; • Type of the equipment and related information about critical items to be

inspected. • Site Location (site map is recommended to be provided) • Instructions for inspections • Contact person on behalf of the IB’s client

(c) Upon arriving at any inspection site, there shall also be an obligation from the IB for the inspector to enquire the following information:

• Information about previous inspections. • If the Inspector cannot obtain sufficient information the inspection must be

treated like a first inspection and therefore proceed with the ‘normal’ inspections.

•• Manufacturing Operations Manual, Operator or Maintenance Manuals of the equipment, safe working load charts in English and/or Arabic language and in case not available and not possible to provide, the IB shall ensure that an independent competent person be engaged by the owner to provide advice and documentation to support the continued use of the lifting equipment, foundations, building ties, engineering drawings, Installation procedures, Inspection procedures, Bolt sizes, grades and torque, Wire rope size, grade and instruction, Markings etc.

The inspector must then, before issuing any Inspection Certificate, address every issue raised in the previous Inspection Report, if any.

(d) The IB shall verify the competency2 of the operator of the lifting equipment to carry out all operations required by the relevant standards, if applicable;

1 Site: Place at which inspection is being undertaken.

2 “Competency of Operator” means in this context that the person who is required to operate the controls of the lifting equipment understands what movement of the lifting equipment will follow when each control is moved and the consequence of each movement of the lifting equipment.




i.e. for some overload tests, the competence of the operator is critical to the safety of the lifting equipment and personnel in the vicinity, according to the applicable standards. The IB shall document the result of verifying the operator competency of the lifting equipment at the time of the inspection, either within the same inspection certificate/ report or in a separate report; specifying the operator name, the equipment for which his competence was checked, the criteria used for verifying his competence and date of inspection.

4.2.2 Inspectors Checklists: • The Inspection Body shall use Checklist forms containing all the

requirements of relevant BS/ EN inspection standards prepared internally and approved by DAC. The checklist forms shall contain sufficient space to indicate the results of evaluating the inspection methods. The Inspector must sign in the checklist after recording all necessary information.

• The Chief or senior Inspector/ Engineer must co-sign the checklist whenever he makes verification visits to the site.

4.2.3 Reporting Defects in equipment under inspection: a) Inspectors are required to be capable of making identification of all types

of defects found in equipment under inspection; if the equipment is found unsafe and represents an imminent danger the IB must advise the owner to cease use of the equipment and report this incident immediately to the EPSS in Dubai Municipality, as per clause (6) of EPSS Technical Guidelines 41.

b) Lifting Equipment Identification: The IB’s must ensure the ability to identify lifting equipment by say Serial Number and Model Number, or some form of Registration Number. If the lifting equipment (and some of their critical components) cannot be identified (even by location in the case of fixed cranes) the IB shall consider this as a defect in the crane which must be reported immediately to related authority in Dubai.

4.3 Inspection Methods and Procedures

4.3.1 Methods and Procedures to be used: The Inspection Body shall use the relevant up-to-date BS and/or BS EN standards in the field of inspection of lifting equipment for performing inspection, as detailed in Annex 13 to this document. In addition to the relevant BS and/or BS EN standards, the manufacturer’s technical literature applicable to the equipment shall also be part of the inspection methods.

3 Annex 1 is subject to review depending on the expansion of DAC scope of services.




It is the responsibility of the Inspection Body to ensure that these requirements and relevant standards detailed in Annex 1 are available at the IB offices.

4.3.2 Inspection Frequencies:

The mandatory inspection frequency intervals pertaining to all Contractors’ “Lifting Equipment” are summarized in Annex 2. General Requirements: a) For all lifting Equipment the first and all subsequent inspections shall

include all functional tests, overload and safety tests. Periodic inspection of “Lifting Equipment” shall also include the following:

• A ‘Periodic Inspection’, which includes: (i) Identification of all critical components and areas; and (ii) Detailed visual inspection of all structural and critical components; and (iii) Tolerance checking where any wear is observed; and (iv) Checking of tolerances for wear limit on critical components; and (v) Checks for corrosion; and (vi) Non-destructive examination of critical areas for evidence of cracking.

• “Non- Destructive Testing” of all lifting connections, attachments and structural components, as directed by the Inspection Body.

b) In the event of a ‘major repair’ the lifting equipment shall be subjected to a

“Periodic inspection” and ‘Proof Load Test” or other inspections specified by a competent person, prior to being returned to normal service.

4.4 Internal Quality Audits

4.4.1 The internal quality audit program shall include the on-site assessment of inspection personnel carrying out inspections.

4.4.2 On-site internal audit shall be carried out by personnel with the relevant

technical qualifications and experience who have been trained in internal auditing and who are sufficiently independent to carry out the audit objectively.

4.4.3 The Inspection Body’s internal quality audit program for on-site audit of

inspectors shall be designed so that within each cycle of the program at least one inspector is assessed thoroughly on site. The program shall also ensure that each of the inspectors engaged in inspection is assessed at least once within a period of 3 years for each of the fields in which they are active.

4.4.4 The audit program shall ensure that where inspections are managed from

locations other than a central location e.g. Branch Offices, including those




located overseas, the audit program encompasses these different locations in a systematic way over the 3 year period of validity of accreditation.

4.4.5 The records of the internal quality audits produced must be in such a way that

will enable the IB to verify the previous inspection works. IBs must describe this point in their Quality Management System Documentation.

4.5 Equipment Used for Inspection

Testing equipments and instruments owned or used by the Inspection Body for testing, measuring, gauging (functional or other tests) of lifting equipment shall comply with the relevant requirements of clause 9 in the ISO/IEC 17020.

4.6 Inspection Certificate/Report

4.6.1 After an Inspection Body has completed an inspection of lifting equipment and

found no significant issues the inspection body must issue an Inspection Certificate for Lifting Equipment.

4.6.2 The Inspection Body shall produce an Inspection Certificate for lifting Equipment on the inspection to fulfill the client’s needs, the related authority requirements and the applicable clauses of BS/ BS EN standards. The certificate shall include the following information as a minimum; the elements of inspection certificates/reports that are considered to be mandatory for compliance with ISO/IEC 17020 are marked with an asterisk (*): 1* Designation of the document, i.e. as an inspection report or an inspection

certificate, as appropriate, 2* Identification of the document, i.e. date of issue and unique identification, 3* Identification of the issuing inspection body Name and address of the IB

issuing / endorsing the certificate, 4* Identification of the client Lifting equipments Owner’s/ Contractor’s name

and address, 5* Description of the inspection work ordered, 6* Date(s) of inspection and Type of Inspection, 7 Information on where the inspection was carried out The address of the

premises at which the Inspection was made, 8 Manufacturer or Supplier of equipment name and address, 9* Identification of the object(s) inspected and, where applicable,

identification of the specific components that have been inspected and identification of locations where e.g. NDT methods have been applied,

10 Unique Identification Numbers, brief description and SWL of the equipment,

11 Any reservations or restrictions on the use or Maximum Capacity of the equipment,




12* Information on what has been omitted from the original scope of work, 13*Identification or brief description of the inspection method(s) and

procedure(s) used, mentioning the deviations from, additions to or exclusions from the agreed methods and procedures,

14 Identification of equipment used for measuring/testing, 15 Where applicable, and if not specified in the inspection method or

procedure, reference to or description of the sampling method and information on where, when, how and by whom the samples were taken,

16*If any part of the inspection work has been subcontracted, the results of this work shall be clearly identified,

17 The Due date of next Thorough Inspection, 18 The Due date of next Proof Load Test, if applicable, 19 Applicable Reference Standard / Code, 20 Details of any major Repairs / Alterations carried out on the equipment,

provided that the clients inform IB’s inspector of any modifications or structural repairs,

21 Details of latest Inspection / Tests previously performed including any NDT if possible,

22 Measuring units (for Loads / Weights) shall be in either/both Metric kilograms or pounds,

23 Information on environmental conditions during the inspection, if relevant, 24* The results of the inspection including a declaration of conformity and any

defects or other non-compliances found (results can be supported by tables, graphs, sketches and photographs),

25 A statement that the inspection results relate exclusively to the work ordered or the object(s) or the lot inspected,

26 A statement that the inspection certificate/report shall not be reproduced except in full without the approval of the inspection body and the client,

27 The inspector's mark or seal, if any, 28*Names (or unique identification) of the staff members who have performed

the inspection and in cases when secure electronic authentication is not undertaken, their signature, (see also clause 13.3 of ISO/IEC 17020),

29 Name, Signature, and Designation of signing Authority of IB, (if different than the inspector who performed the test),

30 Clearly defined Liability Clause of the IB, Certificates issued by third party IBs that fail to give any of the above details

will be liable to rejection by the relevant authority in Dubai.

4.6.3 Professional Judgment that is included in the certificate will form part of the assessment and will be subject to accreditation.

4.6.4 If the inspection commissioned by the client could not be carried out in full or

in part, a written notification to that effect shall be given to the client.




4.6.5 When an Inspection Body undertakes an inspection of Lifting Equipment and

finds items that do not comply with the requirements of the relevant Standards and therefore declines to issue an Inspection Certificate, the IB must issue a separate document called an Inspection Report.4

Re-inspection has to be performed by the same IB for equipment that failed the inspection.

When issuing Inspection Reports, the Related Authority, shall be immediately informed in writing without exception. There would not be any response to the Inspection Reports by the Related Authority unless there is a subsequent accident. They shall remain on file for 12 months – 2 years, after which they will be destroyed (provided Inspection Certificates stay at 1 year currency period).

The Related Authority will conduct follow up action if a second Inspection

Report is received in relation to particular lifting equipment during the period that the Inspection Report remains in their files. The Inspection Report file shall be maintained by the related authority for information in the event of any crane accident.

In the case if there is an accident involving lifting equipment inspected by

accredited IBs and as a result of the official investigation it was determined that the accredited IB was responsible, DAC shall immediately suspend the IB’s Accredited related scope and exclude the inspector who performed the concerned inspection from the authorization list of approved inspectors. Detailed immediate special assessment will be carried out by DAC related to QMS and technical competence of the IB under suspension and subsequently relevant clauses of DAC-REQ-01 related to suspension & withdrawal of accreditation will be applicable. In case the accident involved serious injuries or was fatal, DAC Director reserves the right to withdraw the accreditation for the related scope with immediate effect.

4.6.6 Currency of Certificates of Safety: An Inspection Certificate shall be issued

with a nominal life as specified in Annex 2 of this document. Each Inspection Certificate may be subject to evaluation as determined by the relevant authority and, whenever the lifting equipment is involved in an accident.

4 Inspection Report shall contain the applicable information referred to in clause 4.6.2 of this

document; in addition to the full description as to why the lifting equipment failed the inspection.




However the validity of this certificate is based on the lifting equipment being maintained and operated in accordance with all of the recommendations made by the manufacturer and not suffering any damage.

Therefore the Inspection Body must only issue an Inspection Certificate when it is satisfied that the lifting equipment is likely to be able to perform all the normal lifts within its capacity in accordance with the relevant load chart for at least 12 months.

4.6.7 The designated signatories shall only be authorized by the Inspection Bodies to sign their own Inspection Certificates and Inspection reports. The designated signatory must assume responsibility for the technical validity and accuracy of all information contained in the Inspection Certificate and Inspection Reports.

A designated signatory must have carried out a minimum of inspections for each type of equipment under competent supervision before being authorized to undertake inspections alone. Each Inspection Body shall at the early stage of the implementation process designates appropriately qualified persons to perform the required inspections and that the Approved Signatories provisions of ISO/ IEC 17020 and this document shall be adopted.

5 ACCREDITATION CERTIFICATE

The Accreditation Certificate shall be valid for a period of three years. A Scope of Accreditation detailing the activities for which the inspection bodies have been granted accreditation will supplement the certificate. All inspections not covered by accreditation and currently carried out by the IB under Local Order 52 requirements remain under Local Order 52 requirements.

6 SURVEILLANCE

6.1 Planned Announced Surveillance Visits

The accredited inspection body shall be subject to planned surveillance visits that will be carried out at least two times per year. The purpose of the surveillance visits is to ensure that the inspection body is continuing to comply with the accreditation program requirements. Accredited inspection bodies will be exempted from the regular surveillance visits done as per Local Order 52/ 1990 on-licensed inspection bodies. However, compliance with the requirements of Local Order 52 will be verified during the planned accreditation surveillance visits.




6.2 Planned Unannounced Surveillance Visits

Additional planned special surveillance visits may be carried out at the discretion of DAC and as the need arises without giving prior notifications to the accredited inspection body. Such visits are planned and carried out as per the DAC document DAC-G2-07 “Code of Conduct of the Unannounced Surveillance Visits”.

7 ACCREDITATION FEES

The accreditation fees shall be charged in accordance with the DAC-G2-03 “Accreditation Fee Structure”.

8 ACCREDITATION REQUIREMENTS

The relevant provisions of the DAC-Req-01 “Accreditation Requirements” shall apply to the accredited Inspection Bodies unless otherwise superseded by the provisions of this document.

9 REFERENCES

9.1 Local Order 52/ 1990, on conditions required for licensing laboratories

operating in the emirate of Dubai. 9.2 Local Order 61/1991, on Environment protection regulation in the Emirate of

Dubai. 9.3 Technical Guidelines 41 pursuant to Local Order 61/ 1991, “Examination and

certification of crane, hoists, lifts and other lifting appliances”. 9.4 ISO/ IEC 17020:1998 General criteria for the operation of various types of

inspection bodies. 9.5 IAF/ILAC A4: 2004: Guidance on the Application of ISO/IEC 17020. 9.6 UKAS RG 0-1999: Accreditation for Inspection. 9.7 UKAS RG 6-1999: Accreditation for In-Service Inspection of Lifting Equipment 9.8 LOLER-1998: Safe use of Lifting Equipment: Lifting Operations and Lifting

Equipment Regulations 1998. 9.9 Qatar Petroleum “Lifting Equipment” Technical Regulation QP-REG-Q-001. 9.10 DAC-Req-01 Accreditation Requirements. 9.11 DAC-Req-05 Conditions for using DAC symbol. 9.12 DAC-G2-03 ‘Accreditation Fee Structure’. 9.13 DAC- G2-07 ‘Code of Conduct of the Unannounced Surveillance Visits’. 9.14 ISO 12482-1: 1995, Cranes- Condition Monitoring – Part1: General, 9.15 BS and EN Standards referred to in Annex 1 of this document.




ANNEX 1

LIST OF STANDARDS

PRODUCT TASK NAME STANDARD

Tower Crane Code of practice for safe use of cranes Part 2 (Tower)

BS 7121 - 2:2003 Code of practice for safe use of Cranes - Part 2: Inspection, Testing and Examination Sections 5,6,7,9,12,15

Tower Crane Code of practice for safe use of cranes Part 5 (Tower)

BS 7121:Part 5:2006 Code of practice for safe use of Cranes - Part 5: Tower Cranes Section 14

Mobile Crane Code of practice for safe use of cranes Part 2 (Mobile)

BS 7121-2:2003 Code of practice for safe use of Cranes - Part 2: Inspection, Testing and Examination Sections 5,6,7,9,12,13

Overhead Crane Code of practice for safe use of cranes Part 2 (Overhead)

BS 7121-2:2003 Code of practice for safe use of Cranes - Part 2: Inspection, Testing and Examination Sections 5,6,7,9,12,14

Cranes for Lifting Persons & Suspended Baskets

Code of practice for safe use of cranes Part 2 (Lifting Persons & Suspended Baskets)

BS 7121-2:2003 Code of practice for safe use of Cranes - Part 2: Inspection, Testing and Examination Section 11

Construction Hoist

Code of practice for safe use of Construction Hoist

BS 7212:2006 Code of practice for safe use of Construction Hoist Section 10

Construction Hoist

Builders hoists for persons & materials with vertically guided cages

BS EN 12159:2000 Builders hoists for persons & materials with vertically guided cages Sections 5 & 6

Window/Painter's Cradle

Specification for Suspended Access Equipment

BS 2830:1994 Inc Amdt. No.1 Suspended Access Equipment for use in Building, Engineering construction, Steeplejack & Cleaning industries Section 4

Window/Painter's Cradle

Safety requirements on Suspended Access Equipment

BS EN 1808:1999 Safety Requirements on Suspended Access equipment- Design calculations, Stability criteria, Construction - Tests Section 12 & 13

Escalators

Safety rules for the construction and installation of escalators and passenger conveyors

BS EN 115 : 1995 Incorporating Amendment A1: 1998 Safety rules for the construction and installation of escalators and passenger conveyors




PRODUCT TASK NAME STANDARD

Elevators/Lifts Safety rules for the construction and installation of lifts – Part 1: Electric lifts

BS EN 81-1:1998 Incorporating Corrigendum No. 1 Safety rules for the construction and installation of lifts –Part 1: Electric lifts

Elevators/Lifts Safety rules for the construction and installation of lifts – Part 2: Hydraulic lifts

BS EN 81-2:1998 Incorporating Corrigendum No. 1 Safety rules for the construction and installation of lifts – Part 2: Hydraulic lifts

Elevators/Lifts Safety rules for the construction and installation of lifts – Part 3: Electric and hydraulic service lifts

BS EN 81-3:2001 Safety rules for the construction and installation of lifts – Part 3: Electric and hydraulic service lifts

Elevators/Lifts Safety rules for the construction and installation of lifts — Particular applications for passenger and goods passenger lifts — Part 72: Firefighters lifts

BS EN 81-72:2003 Safety rules for the construction and installation of lifts — Particular applications for passenger and goods passenger lifts — Part 72: Firefighters lifts

Elevators/Lifts Safety rules for the construction and installation of lifts — Existing lifts — Part 80: Rules for the improvement of safety of existing passenger and goods passenger lifts

BS EN 81-80:2003 Safety rules for the construction and installation of lifts — Existing lifts —Part 80: Rules for the improvement of safety of existing passenger and goods passenger lifts




ANNEX 2

ONSHORE “LIFTING EQUIPMENT” FREQUENCIES FOR TESTING / INSPECTION

FREQUENCY FOR LIFTING EQUIPMENT TYPE

PROOF LOAD TEST INSPECTION (SWL)

1 All Lifting Accessories: • Chains and wire ropes • Rings, links, hooks, shackles, eyebolts,

swivels, blocks, snatch blocks • Beam and plate clamps, frames, pallets,

lifting beams and cargo nets

• On initial supply • After substantial alteration

or major repair • At discretion of surveyor

Every six (6) months

2 Lifting Equipments: • Pedestal cranes, mobile cranes,

forklifts, tower cranes • Overhead traveling cranes, wall / pillar

cranes, derricks • Winches, hoist (air and electric), crabs,

Telfer hoist, powered working platforms, vehicle lifts or hoists etc.

• Mobile or movable jacks and associated “Lifting Equipment”

• Lifting Persons & Suspended Baskets*

• On initial supply • Every four (4) years • After reinstallation,

substantial alteration or major repair

• At discretion of surveyor

Every twelve (12) months * Every Six (6) Months

3 • Runaway beams, pad eyes, gin pole and gin wheels

• On initial supply • After reinstallation,

substantial alteration or major repair

• At discretion of surveyor

Every twelve (12) months

4 • Chain Blocks, tirfors, pull lifts, trolleys

• On initial supply • Every four (4) years • After substantial alteration



5 • Lifts – (passenger or goods)

• On initial supply • Every four (4) years • After substantial alteration


Every twelve (12) months

6 • Escalators And Elevators • On initial supply • Every one (1) year • After substantial alteration



Documents

Accreditation Requorements of Inspection Bodies for Lifting Equipment