Saudi Arabian Oil Company (Saudi Aramco) General Instruction Manual Issuing Org.: Subject
Saudi Arabian Oil Company (Saudi Aramco) General Instruction Manual Issuing Org.: Subject
PURPOSE
The purpose of this instruction is to establish requirements and guidelines for the inspection of elevating/lifting equipment
operating on Saudi Aramco projects and facilities. Both Saudi Aramco and contractor equipment are covered.
CONTENTS
1. Definitions
2. Applicable Standards
3. Inspection
4. Marine and Offshore Cranes (Mounted on Barges, Boats and Platforms)
5. Mobile Cranes
6. Fixed Cranes and Hoists
7. Side Boom Tractors
8. Elevators/Escalators
9. Powered Platforms/Sky Climbers
10. Elevating Work Platforms
11. Vehicle Mounted Elevating and Rotating Aerial Devices
12. Articulating Boom Cranes
13. Storage/Retrieval Machines
14. Crane Suspended Personnel Platforms (Manbaskets)
15. Lifting/Spreader Beams
16. A-Frames/Mobile Gantries
1. DEFINITIONS
DESIGNATED PERSON - A person selected or assigned by the owner, or the Saudi Aramco USER department, as
being proficient to perform specific duties and determine if the crane deficiencies constitute a hazard.
DAILY PRE-OPERATIONAL INSPECTION - A visual inspection carried out by a COMPETENT person (Daily,
prior to use, and during shift changes, or whenever operators are changed.)
EXTENSIVE REPAIR - Any repair, alteration or modification to a load sustaining part, gearing, booms,
counterweights, etc.
INITIAL INSPECTION - An acceptance inspection carried out on new, modified, or extensively repaired equipment.
PERIODIC INSPECTION - A visual inspection carried out by a COMPETENT person (Usually quarterly, annually
or after modifications, repairs, or in the case of crawler lattice boom cranes, after relocation or boom re-
configuration.)
USER - Saudi Aramco proponent department or other organization authorized to act on behalf of the Saudi Aramco
proponent department.
2. APPLICABLE STANDARDS
All elevating/lifting equipment covered by this instruction shall be tested and inspected to the relevant ANSI, ASME, API or
other noted Standard. It is the responsibility of Contractors and Saudi Aramco USERS to make themselves familiar with
these requirements:
3. INSPECTION
3.1.1 Prior to daily use, during shift changes or whenever operators are changed, mobile cranes shall have
DAILY PRE-OPERATIONAL INSPECTIONS performed by a COMPETENT person designated by
the USER and using the appropriate daily inspection checklist (See Section 5 of this G.I.).
3.1.2 The USER shall designate a COMPETENT person to carry out a daily pre-operational inspection on all
other elevating/lifting equipment listed in this G.I., using a checklist developed by the USER in
accordance with the manufacturer’s operator’s manual and the relevant standards. The checklist shall
include (if applicable), but is not restricted to, the following:
3.1.3 All deficiencies for mobile cranes and other elevating/lifting equipment shall be reported in the daily
pre-operational inspection checklists.
3.1.4 Any defects, reported in the daily pre-operational inspection, that could affect the safe operation of
mobile cranes and other elevating/lifting equipment shall be corrected prior to use.
3.2.1 The USER shall establish a schedule for PERIODIC inspections of their elevating/lifting equipment in
accordance with the relevant standards.
3.2.2 The USER shall request the Inspection Department to perform PERIODIC inspections on
elevating/lifting equipment that will be operated on Saudi Aramco projects and facilities. PERIODIC
inspections shall be carried out by the Inspection Department in accordance with appropriate standards
referenced in this G.I. The Inspection Department shall witness all load tests.
3.2.3 All elevating/lifting equipment USERS shall request PERIODIC inspections by notifying the Inspection
Department. The notification shall be at least seven (7) days prior to the due date of the inspection.
Remote areas inspections require at least fourteen (14) days notification prior to the due date of
inspection.
3.2.4 The PERIODIC inspection frequency for cranes shall be annual, unless otherwise specified in this G.I.
or as determined by the Inspection Department.
3.2.5 No crane shall be operated unless it has a valid Saudi Aramco Crane Safety Inspection Sticker.
3.2.6 Cranes that have been involved in any type of an incident, causing damage to the crane, shall have their
sticker or certification immediately invalidated. The crane shall not be used until it has passed a re-
inspection. A load test is also required if the damage affects a load bearing member.
3.2.7 All equipment inspections mentioned in this General Instruction, requiring PERIODIC inspections by
the Inspection Department Representative, shall be carried out using an internal inspection checklist.
3.2.8 The USER shall provide all necessary test weights, equipment, and at least one COMPETENT person
to serve as an operator for INITIAL, PERIODIC and any additional load tests. (See G.I. 7.025 for more
information.)
3.2.9 Equipment that has failed the PERIODIC inspection shall be removed from service until all deficiencies
have been corrected, and the crane re-inspected and certified by the Inspection Department. Repairs
shall conform to the manufacturer's instructions and the relevant standards.
3.3.1 All new or EXTENSIVELY repaired, modified, or altered equipment shall have an INITIAL inspection
and a load test prior to putting into service. The load test shall be conducted by the proponent and
witnessed by the Inspection Department.
3.3.2 All new equipment requires a manufacturer’s written test certification to be furnished by the USER to
the Inspection Department prior to the initial inspection.
3.3.3 The INITIAL inspection shall be conducted according to the relevant manufacturer’s recommendations
and relevant standards.
3.4.1 The USER shall furnish the Inspection Department representative with the manufacturer's assembly,
operating, and maintenance instructions for the equipment (in the English language). The USER of the
equipment shall keep copies of these instructions.
3.4.2 Any EXTENSIVE repair, modification, or alteration to any elevating/lifting equipment requires a
manufacturer’s written certification to be furnished by the USER to the Inspection Department upon
request. This certification shall state that the repairs were completed in compliance with the
manufacturer's specifications, Saudi Aramco standards, and by utilizing a COMPETENT person. A crane
jib is considered to be an extension of the main boom and repairs to a jib shall be treated in the same way.
3.4.3 Where the re-rating of equipment is necessary (e.g., crawlers, truck and wheel-mounted cranes, etc.), the
equipment shall be tested in accordance with SAE J765 and other relevant standards. All certification
tests shall be witnessed by the Inspection Department.
3.4.4 When a Load Test is required, the User shall develop a Load Test Procedure and submit it to the
Inspection Department at least seven (7) days prior to the test date.
3.4.5 The Load Test shall be carried out by a COMPETENT person and witnessed by the Inspection
Department.
3.5.1 Records of DAILY PRE-OPERATIONAL INSPECTIONS for all elevating/lifting equipment shall be
maintained by the USER for a minimum of two years and made available for audit. Random audits to
verify daily pre-operational inspections shall be performed by the Inspection Department. Failure to
maintain these records shall result in immediate sticker or certification invalidation.
3.5.2 Records of PERIODIC inspections performed by the Inspection Department shall be maintained by the
Inspection Department for the active life of the equipment.
3.6 Safety
3.6.1 A copy of the manufacturer's operator’s manual (in the English language) shall be made available to the
operator upon request by the USER responsible for the safe operation of any elevating/lifting
equipment.
3.6.2 A sign shall be posted on each crane, warning the operator not to rely solely on any automatic device as
a substitute for safe operating practices (e.g., safe load indicators).
3.6.3 All warning signs required by applicable standards shall be posted in the English language.
4.2.1 Offshore barge and boat cranes shall be approved and certified by the classification society under which
the vessel is registered, and shall be verified during the inspection.
4.2.3 Where no classification society is available, the API Spec 2C (Specification for Offshore Cranes) or the
ASME B30.8 (Floating Cranes and Floating Derricks) standards shall apply.
4.3.1 Pedestal cranes installed on offshore barges or boats shall be designed to comply with the requirements
of the classification society or API Spec. 2C.
4.3.2 Hull structural drawings for connecting foundations of pedestal cranes shall be approved by the
classification society under which the vessel is registered.
4.3.3 For unregistered vessels, a qualified naval architect shall approve foundation drawings in addition to
design calculations.
4.3.4 Load Test Certificates shall be provided by the classification society and certified by a COMPETENT
engineer or marine surveyor.
4.4.1 Deck mounted mobile cranes shall only be installed on barges or boats with decks of sufficient strength
to support wheel, fully extended outrigger, or track loading.
4.4.2 The Inspection Department shall verify that the classification society has approved the deck structural
drawings. They shall clearly state the deck strength that is required to support mobile crane operations.
The drawings shall clearly state the maximum permissible bearing pressure on deck plating and show
the boundary of all permissible crane operating areas.
4.4.3 Deck mounted mobile cranes installed on barges or boats shall comply with G.I. 7.024.
4.4.4 Trim-and-stability-books (in the English language) are required to install and operate deck mounted
mobile cranes on barges or boats. They must comply with the requirements of IMO SOLAS regulations
showing loading conditions that take into account the specific crane operation.
4.4.5 Mobile cranes installed on barges or boats, and their dynamic load charts, shall be approved by a
COMPETENT engineer for offshore use.
4.4.6 All main boom sections, including power pinned section, shall be extended and inspected for corrosion,
proper operation and damage.
4.5.1 Offshore cranes shall receive a PERIODIC inspection every ninety (90) days or as determined by the
Inspection Department.
5. MOBILE CRANES
5.2.1 All mobile cranes shall have a conspicuously posted load chart and range diagram stating lift capacity
based on boom length, attachments, boom angle, outrigger configuration, radius, and lift quadrant.
Instruction plaques shall be permanently affixed to the cab of the crane where it is available to the
operator while he is seated at his control station. Environmentally protected books may be approved as
an alternate to plaques. (All plaques and books shall be in the English language.)
5.2.2 A sign warning of the danger of overhead power lines shall be mounted on each mobile crane where it
can be easily seen by the operator. This sign shall warn that the crane must not be operated if any part
of the crane will come within the following minimum distances of energized power lines:
5.4.1 Mobile cranes shall receive a PERIODIC inspection every ninety (90) days or as determined by the
Inspection Department.
5.4.2 The operator of a Saudi Aramco owned mobile crane shall perform a daily pre-start safety inspection,
prior to operating his assigned crane, on Saudi Aramco form SA 9466. All Saudi Aramco mobile crane
deficiencies shall be reported DAILY to the Area Roads and Heavy Equipment Department. (See G. I.
7.028 for more information.)
The contractor mobile crane operator shall perform a daily pre-start safety inspection, prior to operating
his assigned crane, by using the crane manufacturer’s daily inspection checklist or Saudi Aramco form
SA 9466. All contractor mobile crane deficiencies shall be reported DAILY to the contractor mobile
crane operator’s direct supervisor. (See G. I. 7.028 for more information.)
5.4.3 The USER shall furnish the Inspection Department representative the appropriate manufacturer's
assembly, operating, and maintenance instructions for the crane, when so required (in the English
language).
5.4.4 All main boom sections, including power pinned sections, shall be extended and inspected for corrosion,
proper operation, and damage.
5.4.5 If equipped, swingaway boom sections shall be inspected for corrosion and damage.
5.4.6 Any assembling, disassembling or change of lattice boom configuration requires re-inspection by the
Inspection Department.
6.1 Inspection and Testing Requirements per ASME B30.2, B30.3, B30.4, B30.6, B30.7, B30.11, B30.16 & B30.17
6.1.1 Fixed cranes and hoists covered by ASME Standards shall receive a PERIODIC annual inspection or as
determined by the Inspection Department.
6.1.2 Any fixed crane that is relocated, repaired, modified, or altered shall be retested prior to use.
6.1.3 Any EXTENSIVE repair, modification, or alteration to a fixed crane requires a manufacturer’s written
certification to be furnished by the USER to the Inspection Department upon request. This certification
shall state that the repairs were completed in compliance with the manufacturer's specifications, the
applicable ASME standards listed above, Saudi Aramco standards, and by utilizing a COMPETENT
person.
7.1.1 Side boom tractors shall receive a PERIODIC inspection every ninety (90) days or as determined by the
Inspection Department.
7.1.2 Any EXTENSIVE repair, modification, or alteration to sideboom tractors requires a manufacturer’s
written certification to be furnished by the USER to the Inspection Department upon request. This
certification shall state that the repairs were completed in compliance with the manufacturer's
specifications, ASME B30.14, Saudi Aramco standards, and by utilizing a COMPETENT person.
8. ELEVATORS/ESCALATORS
8.1.1 Elevators and Escalators shall receive a PERIODIC annual inspection or as determined by the
Inspection Department.
8.1.2 Braking System and Car & Counterweight Safeties shall be tested at three (3) and five (5) year intervals
respectively or as determined by the Inspection Department.
8.1.3 The USER shall furnish the Inspection Department with the appropriate manufacturer's assembly,
operating, and maintenance instructions, upon request (in the English language).
9.1.1 Powered Platforms/Sky Climbers shall receive a PERIODIC inspection every ninety (90) days or as
determined by the Inspection Department.
9.1.2 The initial inspection and load test shall be carried out whenever a Powered Platform/Sky Climber is
installed or relocated. The load test shall be conducted by the USER and witnessed by the Inspection
Department.
9.2 Safety
9.2.1 Powered platforms for permanent installations shall be used according to the requirements of ANSI
A120.1.
10.1 Inspection and Testing Requirements per ANSI A92.3, A92.5, & A92.6
10.1.1 Elevating work platforms shall receive a PERIODIC inspection every six (6) months or as determined
by the Inspection Department.
11.1.1 The USER is solely responsible for developing a PERIODIC inspection and testing program on the
electrical insulating components and systems per ANSI A92.2. The results of the electrical testing and
inspection shall be made available to the Inspection Department for review prior to performing the
PERIODIC mechanical inspection.
11.1.2 Vehicle Mounted Elevating and Rotating Aerial Devices shall receive a PERIODIC inspection every six
(6) months or as determined by the Inspection Department.
12.1.1 Articulating boom cranes adapted for marine and offshore use shall meet the installation requirements
of Section 4 of this G.I.
12.1.2 Articulating boom cranes shall receive a PERIODIC inspection every ninety (90) days or as determined
by the Inspection Department.
13.1.1 Storage/Retrieval Machines shall receive a PERIODIC annual inspection or as determined by the
Inspection Department.
14.1 Inspection and Testing Requirements per ASME B30.5 & B30.23
14.1.1 Crane suspended personnel platforms (manbaskets) shall receive a PERIODIC inspection every six (6)
months, or when dedicated rigging has changed, or as determined by the Inspection Department.
14.1.2 DAILY PRE-OPERATIONAL INSPECTIONS and pre-lift proof load tests shall be carried out by a
COMPETENT person designated by the USER, in accordance with G.I. 7.027.
14.1.3 Personnel platforms (manbaskets) shall meet all Saudi Aramco fabrication specifications/requirements.
The USER may also be required to submit additional fabrication design information to the Consulting
Services Department for review and concurrence, prior to certification by the Inspection Department.
15.1.1 Lifting/spreader beams shall receive a PERIODIC inspection every six (6) months, or as determined by
the Inspection Department.
15.1.2 An inspection shall be performed by a COMPETENT person designated by the USER, prior to each lift.
15.1.3 Lifting/spreader beams require an initial load test of 125% of the rated safe working load. This test shall
be witnessed by the Inspection Department.
15.1.4 Lifting/spreader beams shall meet all Saudi Aramco fabrication specifications/requirements. The USER
may also be required to submit additional fabrication design information to the Consulting Services
Department for review and concurrence, prior to certification by the Inspection Department.
16.1 Inspection and Testing Requirements per ASME B30.11 & B30.16
16.1.1 A-frames/mobile gantries shall receive a PERIODIC annual inspection or as determined by the
Inspection Department.
16.1.2 A pre-inspection shall be performed by a COMPETENT person designated by the USER prior to each
use.
16.1.3 A-frames/mobile gantries shall meet all Saudi Aramco fabrication specification/requirements. The
USER may also be required to submit additional fabrication design information to the Consulting
Services Department for review and concurrence, prior to certification by the Inspection Department.
Recommended:
Manager, Inspection Dept.
Recommended:
Manager, Loss Prevention Dept.
Recommended:
Manager, Roads & Heavy Equipment Dept.
Recommended:
Director, Job Skills Training Dept.
Concur:
Vice President, Industrial Services
Approved:
Vice President, Engineering Services